Objective: To explore the application of advanced data analysis techniques in evaluating the effectiveness of multiple skin expansion procedures on scar plastic surgery outcomes following neck burns, with a focus on functional recovery, patient satisfaction, and implications for physical rehabilitation and sports performance. Methods: This study utilized big data processing and machine learning techniques to analyze clinical data from severe burn patients. Data preprocessing was performed, followed by unsupervised algorithms such as hierarchical clustering and principal component analysis to identify patterns and subgroup classifications linked to clinical outcomes. Sixty patients with post-neck burn scars who underwent scar plastic surgery were included. Clinical parameters such as scar blood flow values and pruritus symptom scores were analyzed to evaluate the impact of skin expansion procedures. Results: In the early post-burn phase, patients often experienced local thickening, hardening, and extreme capillary congestion leading to pruritus. The results showed significant reductions in both scar blood flow values and pruritus symptom scores in all patients. However, patients in the observation group, who underwent multiple skin expansion procedures, exhibited greater improvements (P < 0.05). These findings align with prior research, confirming the effectiveness of the intervention and its potential benefits for enhanced recovery. Conclusion: The use of multiple skin expansion techniques in scar plastic surgery following neck burns significantly improves clinical outcomes, including reduced scar vascularity and pruritus severity, thereby promoting better functional recovery. These advancements have direct implications for physical rehabilitation, facilitating greater mobility and quality of life, and enabling patients to engage in physical activity and sports with improved confidence and comfort. Further research integrating machine learning-based prediction models can enhance personalized rehabilitation strategies for burn survivors.