Abstract: As the core equipment in the fields of national defense security, resource development, and emergency support, special vehicles need to meet strict requirements such as high load-bearing capacity, impact resistance, lightweight, and extreme environmental adaptability for key components such as frame beams, protective armor, and lifting booms. Q960 high-strength steel has become the core choice for upgrading special vehicle materials due to its ultra-high yield strength of ≥960 MPa, excellent low-temperature toughness, and good process adaptability. This article systematically analyzes the material characteristics and composition design logic of Q960 high-strength steel, combined with the diverse service conditions of special vehicles, from structural design optimization, processing technology control, forming process control, corrosion protection technology, etc., comprehensively explores its application technology path and structural manufacturing in special vehicles, and provides theoretical support and practical reference for the upgrading of lightweight and high-performance special vehicles.