In order to achieve the most optimal lightweighting of titanium alloy blades, the combined diffusion bonding–superplastic forming (DB/SPF) technology has been increasingly employed in the preparation of blades. The blades produced by this technique exhibit specific thin-walled and reinforced internal structures, with the geometrical stress concentration at the juncture of these internal structures representing the primary initial crack initiation point during blade operation. This chapter considers the design of welded structures for the diffusion joining–hyperplastic forming process and proposes the introduction of preset non-welded holes to achieve control of the maximum curvature of the surface geometry in the structural forming. This is intended to alleviate stress concentration in the final blade structure through the development of the process. Furthermore, this chapter presents a process simulation analysis of the forming process for a specific titanium alloy blade, investigating the relationship between the length and position parameters of the preset non-welded holes and the surface curvature. This analysis paves the way for the establishment of an optimization method and model of the process parameters, with the aim of enhancing the structural performance of the blade. The results of the calculations demonstrate that the incorporation of non-welded holes can effectively reduce the maximum surface curvature of the internal structure of the blade by approximately 25%. This substantiates the efficacy of this design concept in mitigating stress concentrations in the thin-walled structure of titanium alloy blades.