We optimized hot stamping process parameters for 2 mm boron steel (22MnB5) to enhance the mechanical properties and defect prevention of ultrahigh-strength steel components. Utilizing an orthogonal experimental design and numerical simulation, we analyzed the effects of heating temperature, holding time, and cooling water flow rate on the microstructural evolution and mechanical performance of the stamped parts. The results indicate that a heating temperature of 930 ℃, a holding time of 4.5 min, and a water flow rate of ≥0.75 m/s must be maintained in the optimal process. Verification using these parameters presented a transformed, uniform lath martensitic microstructure with a tensile strength of 1535 MPa and a hardness exceeding 48 on the Rockwell C scale. By integrating a sensor monitoring system into the die design, process stability and tool safety can be ensured. By employing embedded piezoelectric force sensors to detect the volumetric expansion associated with the martensitic phase transformation and noncontact pyrometers for thermal history verification, the system enables a closed-loop control mechanism. This sensor-driven approach enables the precise, piece-by-piece optimization of quenching time, significantly preventing defects and ensuring the consistent quality of high-performance automotive components.