A parameter optimization method based on sensitivity analysis is presented for the structural optimization of variable section slender manipulator. Structure mechanism of a polishing robot is introduced firstly, and its stiffness model is established. Then, a design sensitivity analysis method and a sequential liner programming (SLP) strategy are proposed. In the beginning of the optimization, the design sensitivity analysis method can be used to select the sensitive design variables which can make the optimized results more efficient and accurate. And then, it can be used to improve the convergence during the process of the optimization. The design sensitivities are calculated using the finite difference method. The search for the final optimal structure is performed using the SLP method. Simulation results show that the structure optimization method is effective to enhance the stiffness of the manipulator, no matter when the manipulator suffers constant force or variable force. This work lays a theoretical foundation for the structural optimization for such manipulators.