The invention discloses an optimal design method of a heat exchanger plate, which comprises the following steps of: according to the parameter requirements and the restriction conditions on the heat exchanger plate, setting up a material database for a material forming performance test; setting up a die model and a standard sample database; simulating the punching process of the heat exchanger plate, comparing with the standard sample database and analyzing the defects of the plate in a simulating and punching process to judge whether the simulating result accords with a test specification ornot, if not, adjusting the topological structure of a die and the geometric dimensions of the local positions, and then carrying out analysis and a simulation test again until the simulating result completely accords with the test specification; outputting various parameters of the die corresponding to the heat exchanger plate with the simulating result according with the test specification; and manufacturing the die. The optimal design method integrates the two steps of trial-producing a sample plate and reforming the die in the traditional method into a digital manufacturing link, thereby reducing the blindness in design, avoiding the scrapping of the die and shortening the development cycle of the heat exchanger plate.