Abstract: The lightweight design of bend pulley structures holds significant engineering importance for the safe and reliable operation of belt conveyors. Firstly, static analysis and dynamic modal analysis were conducted using the finite element numerical simulation method, laying the foundation for the optimization design of the pulley. Secondly, employing the response surface optimization method combined with BBD experimental design method, a mathematical optimization model was established. In this model, the pulley's wall thickness, hub thickness, and inner diameter were taken as design parameters, the pulley mass was set as the objective function, and the maximum deformation, maximum stress, and vibration frequency of the pulley were used as constraint conditions. Subsequently, the sequential quadratic programming method was adopted to solve the model, thereby obtaining the optimized parameters. Finally, the optimization results indicate that, while satisfying the requirements for maximum deformation, maximum stress, and vibration frequency under the deformation criteria, the overall mass of the bend pulley was reduced from 1288.4 kg to 1132.46 kg, achieving a 12.1% reduction in the structural mass of the pulley. The research results not only provide theoretical guidance for resource conservation in the research, development, and manufacturing of bend pulleys for belt conveyors but also offer methodological support for the vibration characteristics analysis and structural design of pulleys.