Based on the differential manifold theory, a design method of robust dynamic boundary protection system for ice formation on aircraft is proposed. First, the dynamic boundary of preice formation on aircraft is calculated by the differential manifold theory, and its accuracy and efficiency are verified by Monte Carlo method. Secondly, taking the influence model of icing factor as foundation, the variation rule of aerodynamics boundary under different icing degree is studied and analyzed. Then a robust dynamics boundary of aircraft is proposed, and a robust dynamic boundary protection system for aircraft under ice condition is designed. Compared to the traditional dynamic boundary, it is not necessary to obtain accurate ice type information and ice severity when the aircraft encounters icing adverse flight environment. In consideration of the current ice detection technology, the method proposed in this paper has more extensive engineering application significance. Before the aircraft goes beyond the dynamic boundary, the boundary protection system can keep the flight state within the safety threshold, ensuring the safety and controllability of the aircraft.