6xxx aluminum alloys have been increasingly used to make the autobody outer panels. Since 6xxx alloys are typically less formable than mild steels, it is often a very challenge task to make aluminum outer panels with the steel kind sharper features. This paper demonstrates an advanced practice in draw die development, material modeling, simulation approach and part formability assessment. The unique technology developed enables the desired aluminum outer panel geometry formed with the critical styling features which was thought impossible. By means of the FEA simulations, the tooling geometry, draw bead configurations and lubricant effect were investigated and optimized. It ensured the optimal balance of material stretching and desired plastic deformation. Furthermore, a new formability assessment method was developed to evaluate part global formability and local featured-based formability. The current development was validated by the tryout results showing an excellent match between the simulations and argus measurements.