Abstract: This study investigated the quality issue of hydrogen-induced brittle cracking and poor compatibility with spot welding in hot-formed boron steel part produced by a manufacturer during process commissioning. The direct hot stamping process of boron steel was optimized based on microstructural control using optical microscope (OM), Vickers hardness tester, tensile testing machine, and scanning electron microscope (SEM). It was found that the manufacturer’s production line did not precisely control the lower limit of heating time, resulting in insufficient austenitization due to inadequate heating during hot forming process. The mechanical properties of this hot-formed part were at the lower specification limits, and its microstructure contained a small amount of blocky ferrite and blocky retained austenite. During hot stamping, wrinkles formed in Al–Si coating, and microcracks initiated. Subsequently, under the combined influence of restraint stress from resistance spot welding and hydrogen atoms, hydrogen-induced delayed cracking occurred at stress concentration site on the surface of the hot-stamped part. By appropriately extending the heating time and improving the mold surface conformity rate, the manufacturer optimized the process for this hot-formed steel part. As a result, the heat treatment microstructure defects were eliminated, and the problem of poor spot welding compatibility was resolved.