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According to the actual technical requirements of radar equipment testability optimization design, the process of radar testability optimization design is analyzed. Based on the data of each stage of radar equipment and considering the factors of test efficiency, test cost and reliability constraint, the test optimization method based on test cost and test efficiency is studied, and the test optimization model of radar system based on minimum test cost is given. An improved particle swarm optimization algorithm is proposed to solve the multi-objective optimization problem. The chaos theory is introduced into the algorithm, which makes the initial population diversified, avoids the premature phenomenon of traditional particle swarm optimization, and improves the search accuracy and speed. Through the simulation and verification of the case, it is shown that this improved particle swarm optimization algorithm can obtain the global optimization model based on the minimum test cost under the constraints of the objective function of the model.