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The tailgate‐extension in a vehicle is a part that connects the upper and lower parts of the tailgate. Since this part does not require high strength, aluminum must be used in order to reduce the weight of the vehicle. However, when choosing aluminum, it is difficult to satisfy the shape quality with the existing manufacturing process. Therefore, this study was conducted for the purpose of optimizing the draw metal stamping process for the development of tailgate extensions for vehicles using aluminum. The response surface methodology was utilized to optimize the draw metal stamping process. The process design parameters were established as blank holding force, coefficient of friction and die speed. Finally, the reliability of the optimization process and finite element analysis was secured by conducting field experiments to review the derived optimal process conditions. [ABSTRACT FROM AUTHOR]