This paper introduces a design method for expandable subarray structures used in phased array radar arrays. Based on the structural characteristics of modular subarray layout for large radar arrays, this paper analyzes the assembly dimension chain tolerance based on subarray expansion. One third of the allowable deviation of the radar array is used as the subarray design tolerance, and the size tolerance of each installation surface of the subarray is designed according to the design tolerance. Finally, the subarray array is assembled into any size of radar array, and the probability of the radar array assembly accuracy meeting the allowable deviation is 99.73%. For large radar arrays, adopting this design method can significantly reduce the tolerance span between the sub array and the area array, greatly reducing the difficulty of design and processing. This paper provides a fundamental design method for the expansion design of radar arrays with similar systems, which has universal applicability.