To address the engineering challenge of dynamic instability in high-speed aircraft wing rudder structures under extreme thermo-vibratory coupled loads, this study proposes an innovative method of structural design and manufacturing integration based on high-temperature alloy additive manufacturing technology. Initially, a multi-objective topology optimization model is established for the synergistic optimization of rigidity and dynamics. The topological framework is reconstructed in alignment with additive manufacturing constraints, while integrating the three-dimensional lattice filling strategy to achieve the multi-functional coupled design of load-bearing, vibration-damping, and heat-dissipation. Subsequently, the topologically reinforced rudder structure with a lattice core layer is fabricated through the high-temperature alloy additive manufacturing technology, and the advanced heat treatment processes are implemented to mitigate residual thermal stresses, enhance the overall rigidity of the structure, and improve the fatigue resistance of the material. The thermal modal characteristics of the rudder structure are experimentally determined through thermal modal tests, demonstrating strong agreement with numerical simulation results. The integrated technical method proposed in this paper breaks through the technical bottlenecks of traditional process schemes. Through the design-manufacturing collaboration mechanism, it can reduce the frequency of design iterations in the actual manufacturing process. Under the dual constraints of structural rigidity and dynamic stability, the full-process integration from design to integrated molding manufacturing of complex components is achieved. This methodology provides an engineering implementation pathway for next-generation hypersonic vehicle structures requiring integrated thermal protection and load-bearing capabilities.