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It’s crucial for process engineers to determine optimal value and combination of process parameters in the design of sheet metal forming. The multi-objective genetic algorithm (MOGA) based on Pareto approach and numerical simulation codes were integrated in this paper to fulfill the optimal formability in the sheet metal forming. Three objective functions of local formability on fracture, wrinkling and insufficient stretching were presented based on the strains state at the end of the forming process on the Forming Limit Diagram. By using Pareto-based MOGA, the optimal global formability which represents the trade-off between different local formability was decided. For the efficiency and accuracy of optimization procedure, both inverse and incremental finite element analysis were used to evaluate the value of objective functions. This method was applied to a complex engineering optimization problem: an engine hood outer panel, the optimal blank holder force and draw bead restraining forces were determined to satisfy the given objective functions for the forming of the auto body panels. The approach proposed in this paper has been shown to be a powerful tool than manual numerical simulation procedure. © 2005 American Institute of Physics [ABSTRACT FROM AUTHOR]