AbstractThe forming tools are conventionally manufactured from alloy steels. These tools can be designed to be light weight and cost effective without compromising performance characteristics. In this research, a fundamental forming tool (pressure die) of ‘rotary draw bending processes’ is topology optimized and 3D printed by using polymeric material. An accurate FE-simulation model of a rotary draw bending process is developed and topology optimization of the pressure die is carried out on the basis of contact stresses provided by FE-simulation results. The topology optimized pressure die is compared with its conventional metal made counter-part in terms of contact forces, contact normal stresses, effective area in-contact and cost performance index. This manuscript demonstrates that topology optimized lightweight 3D printed polymeric forming tools are a cost effective alternative to comparatively heavy alloy steels. This research contributes to widen the avenue of cost effective manufacturing by incorporating topology optimization regimes into existing production setups.