Objective To perform structural optimization for a self-designed EPS cushion. Methods First the drop analysis was conducted using HyperWorks and LS-DYNA, then OptiStruct was used to perform topology optimization, combining with simulation and related data, and finally the results before and after optimization were compared. Results The maximal impact acceleration value of the FPTV impacted was less than 45 g after the cushion structure optimization, meeting the requirement of buffering. Conclusion The cushion structure was optimized, and topology optimization provides very beneficial exploration and reference for such problems.