Hot Form Quench (HFQ®) is a disruptive hot forming technology, recently developed, to produce cost-effective, complex-shaped, high-strength aluminium panels. The objective of this study is to develop an advanced methodology to guide optimal design for manufacturability using HFQ® Technology, through tackling a cutting-edge design challenge in the automotive industry for creating battery boxes with deep corners for EVs. In this study, a demonstrator model is first designed. Then, experimental and numerical tests are carried out, based on aluminium alloy 6082, to obtain the correlation between design variables, as well as their relationship with forming parameters. As last, optimisation algorithms are implemented to explore the optimal design with maximum drawing depth and minimum bottom corner radii. The advanced formula and the understanding of the design challenges developed through this study will enrich the design guides for HFQ®.