The paper was aimed to optimize the cushion packaging structure for Dell notebook Vostro 1440. Based on the product characteristics and circulation environment, the cushion packaging material was determined, and three sets of cushion packaging structure improvement schemes were designed and comparatively analyzed with the original scheme. The cushion packages with the optimal design and the original design were tested with drop simulation security analysis via Ansys software. Using EPE with a density of 0.029 g/cm3 as the cushion material, all three sets of improvement schemes saved material consumption to different degrees and passed the deflection check. Scheme 3 has the least material consumption and was multifunctional, besides, it showed better cushioning effect than the original cushion structure in the dropping simulation. In conclusion, product cushion packaging structure has a development trend towards environmental friendliness, high efficiency, low cost, and multi-function.