<p>The electrically assisted stretch bending (EASB) process enables the fabrication of components with complex cross-sections. However, defects such as springback, wrinkling, and necking typically emerge in this process. This study proposes a process parameter control methodology based on defect formation mechanisms and establishes an optimization framework to mitigate and prevent these defects and improve product quality. Analysis of the wrinkling and necking mechanisms elucidated the effects of process parameters on defect formation. Based on this foundation, defect prevention criteria were formulated as constraints, whose solution defined the feasible region of design variables. Subsequently, a springback optimization framework was developed using a response surface surrogate model. A case study on Y-section profile EASB demonstrates the framework’s implementation through five key steps: finite element modeling, stress-neutral layer determination, initial wall-thickness defect incorporation, feasible region definition, and springback optimization model construction and solution. Results demonstrate that optimizing process parameters within this framework effectively reduces springback while preventing wrinkling and necking.</p>