The rising complexity of civil aviation and recent incidents, including Sichuan Airlines “14 May” and China Eastern Airlines “21 March,” highlight the urgent need for real-time flight data acquisition systems to support timely safety monitoring and early warning. Current methods rely mainly on post-flight data, while real-time monitoring remains constrained by limited bandwidth and insufficient device capabilities. This study presents a comprehensive structural and mechanical analysis of a real-time flight data acquisition device designed according to ARINC-600 standards and airworthiness regulations (ED112A, DO-160G). The device integrates data acquisition, storage, processing, and power modules, utilizing a Xilinx Zynq UltraScale™ platform for hardware-software co-processing, enabling high-speed data parsing, time synchronization, encryption, redundant storage, and secure transmission. Finite element modal analysis was performed to evaluate the structural airworthiness and vibration characteristics. The first ten natural frequencies range from 246.41 Hz to 1109.2 Hz, significantly exceeding typical aerospace excitation frequencies, effectively preventing resonance under operational conditions. Mode shape analysis indicates an evolution from low-order global bending and torsion to high-order local complex deformations, revealing relative stiffness weaknesses at panels and connection points, providing guidance for structural optimization. The study establishes a closed-loop framework connecting mechanical characterization, data security, and equipment reliability. Combined simulation and experimental validation ensures accurate assessment of dynamic performance, supporting operational robustness and airworthiness. The findings not only advance the development of high-performance real-time flight data acquisition systems but also enhance risk identification, early warning, and overall flight safety management in civil aviation.