This study addressed the cracking problems of high borosilicate glass lamp covers observed during whole-machine aging tests by implementing a comprehensive optimization strategy. Key improvements were achieved through three approaches: production process refinement, chemical composition adjustment, and structural design innovation. The production process was enhanced by upgrading melting furnaces, optimizing melting procedures, introducing automated compression molding equipment, modifying annealing curves, and implementing robust packaging solutions. Chemical modifications focused on adjusting the glass formula to reduce its thermal expansion coefficient and improve thermal stability. Structurally, stress concentration issues were mitigated through optimized head geometry, increased fillet transitions, and redistributed mechanical stress. Post-optimization results demonstrated a stabilized production qualification rate exceeding 75%, with the redesigned lamp covers successfully passing stringent performance evaluations, including thermal shock resistance tests (ΔT ≥ 105 ℃) and 3 000 h aging assessments. This systematic approach provided valuable insights for enhancing the reliability of high borosilicate glass products, offering actionable methodologies for advancing manufacturing techniques in specialty glass applications. The findings contributed to both academic understanding and industrial practices in addressing stress-related failure mechanisms in high-performance glass components..