This study selected six types of external fibers and implemented differentiated beating processes according to their fiber characteristics. The impacts of classified beating on fiber properties, hot water-soluble content and physicochemical properties of reconstituted tobacco sheets, as well as sensory quality of cigar were systematically evaluated to identify the optimum external fiber type. The results demonstrated that the reconstituted tobacco base sheets prepared through classified beating exhibited superior flatness, improved bulk and formation uniformity with reduced two-sided variation. The surfaces showed minimal visible large particles, facilitating uniform distribution and vertical penetration of coating solutions. The optimized base sheets incorporating Manila hemp pulp with beating degree of 43 °SR as external fibers developed a refined pore structure characterized by increased quantity and reduced pore size, enhancing both permeability and retention uniformity of coating solutions. Post-optimization characterization showed that the reconstituted tobacco sheets displayed a notable thickness increase approaching double that of base sheets, accompanied by significantly enhanced cross-sectional porosity.