<p>The production of aero engine casings requires forming Ti-6Al-4V cylinders with low aspect ratios. Compared to conventional thermal forming, electrically assisted forming demonstrates higher efficiency and leverages non-thermal effects to enhance the plastic deformation ability of Ti-6Al-4V titanium alloy. The electrically assisted differential thermal bulging, combining characteristics of thermal/electrically assisted forming, produces the cylinder components that maintain peak tensile strength among all experimental conditions across 25–350℃ under lower effective currents and forming temperatures. During bulging process design, the finite element methods were performed to optimize electrode quantity and spacing, which aims to alleviate thermal expansion and achieve uniform electrical/thermal distribution. The cylinder components produced via this novel approach exhibit only 40% of the roundness error observed in traditional thermal forming. It attributes to friction force reduction through stress alleviation induced by non-thermal electroplasticity. Microstructural characterization revealed that the transition from equiaxed α phases to bimodal microstructures in electrically assisted formed specimens was primarily caused by excessive temperatures. The electrically assisted differential temperature bulging, which retains equiaxed α phases, weakens texture intensities more severely than pure electrically assisted forming with higher current/temperature. These findings confirm the new forming technology improves microstructure homogeneity and facilitates precision forming of the Ti-6Al-4V cylinder with a low aspect ratio.</p>