The rapid urbanization and industrial growth have increased the demand in construction, maintenance, and infrastructure, leading to significant advancements in aerial work vehicle technology. This study focuses on the structural performance of ultra-high-strength steel plates of varying thicknesses used in telescopic booms, which is a critical component of aerial work vehicles. This study aims to address the cost issues associated with the previously used 5mm thick plates by evaluating the structural integrity of thinner plates. Using finite element analysis (FEA), the study analyzes stress and displacement for different thicknesses, specifically targeting the first boom segment, which bears the most load. The results indicate that while 3mm and 3.2mm thick plates are unsuitable due to buckling, the 4mm thick plate meets safety criteria with a safety factor of 2.51 and reduces costs by over 20%. By using 4mm thick ultra-high-strength steel for the first boom segment is cost-effective, providing structural integrity and an applicable solution for aerial work vehicle manufacturers.