In response to the demands for miniaturization, non-polarity, high short-circuit resistance, state monitoring, and high reliability of high-voltage DC contactors for the 800~1500 V high-voltage platform of new energy vehicles and energy storage systems, this paper is based on the Cassie arc model and magnetic blowout arc extinguishing theory. It optimizes the arc surface contact structure and magnetic blowout path to improve the arc extinguishing performance, uses multi-physics field simulation and a self-developed anti-short-circuit electromagnetic repulsion cancellation structure to enhance short-circuit tolerance, optimizes the magnetic circuit and coil parameters, and reconstructs the Pulse Width Modulation (PWM) intelligent drive algorithm to reduce coil power consumption and temperature rise; optimizes the insulation creepage path to adapt to extreme conditions such as high altitude and low temperature; innovatively designs an integrated auxiliary contact structure, and adopts special processes such as ceramic vacuum brazing and filler sintering. Finally, a large current, miniaturized, and highly reliable ceramic sealed high-voltage DC contactor is developed, achieving non-polarity breaking and real-time state monitoring of the auxiliary contacts. This product has been granted an invention patent and has passed a complete type test and real vehicle installation verification, providing a complete engineering reference for the forward structure design of high-voltage DC contactors.