Abstract: For the problem of a certain cylinder’s inner cavity dimensions failing to meet technical requirements due to deformation during heat treatment, the collaborative optimization of "process-structure" to achieve accurate forming of aluminum alloy cylinder castings was focused on. By optimizing the heat treatment process and adding axial and radial stiffeners ribs to control deformation, the experimental research was conducted. The results show that optimizing the heat treatment process alone has only a minor effect; optimizing the process and adding axial stiffeners can prevent deformation in a certain content, but still does not meet the requirements. By adding radial stiffeners on the basis of the above two measures,combined with thermal aging to remove residual stress, the anti-deformation effect is significant, the internal cavity dimensions of the product meet the technical requirements. Finally, the measures such as printing the whole core, optimizing heat treatment process parameters, setting axial and radial stiffeners, combining with thermal aging treatment were adopted to achieve precise forming of the cylinder.