The series cooperative manipulator based on size optimization and topology optimization combined with global finite element analysis satisfies lightweight design of structure. Firstly, the initial design of cooperative manipulator structure is carried out with reference to the existing cooperative manipulator and size optimization design. Secondly, when the cooperative manipulator is in the limit state, the finite element analysis and topology optimization of each joint are carried out based on the joint global finite element analysis method. Finally, based on the topology optimization results, the joint structure of the cooperative manipulator is reconstructed and verified by simulation. The results show that the structure of the cooperative manipulator can meet the requirements of strength and stiffness in normal operation, reduce the dead weight of the cooperative manipulator structure and realize the lightweight design of the cooperative manipulator structure based on the topology optimization design of size optimization and combined whole finite element analysis.