<p>Stretch forming is a critical process in the manufacturing of large aircraft skin components. The loading amount and trajectory of clamping jaws play a significant role in achieving the desired component quality. Traditional design methods, relying on estimation, experience, and trial-and-error, often fall short in producing skin components with the required precision. The stretch forming of aluminum is particularly challenging due to the material’s elastic recovery, which complicates the accurate shaping of components. In addition, aircraft body design has become increasingly complex, driven by demands for better fuel efficiency, higher speed performance, and improved stealth capabilities. These advancements have led to the development of skin panels with intricate shapes and varying curvatures, making the production of these parts significantly challenging. This study investigates the stretch forming process of a complex aircraft panel, with a focus on the influence of die displacement and clamping jaws trajectory on sheet thickness, wall curling, and springback. The simulation and experimental findings demonstrate that an optimized design of the clamping jaw positions and wrapping angles significantly reduces springback and improves the thickness and the accuracy of the formed parts. These results provide valuable insights and guidelines for controlling defect occurrence during stretch forming.</p>