Recent manufacturing developments, which focus on optimum product fabrication technique, including thermoforming, are time-consuming and cost-effective. Fundamental studies of the thermoforming process; especially in a uni-directional direction of Kenaf fiber composite, are still in their preliminary stages. Hence, a numerical simulation is performed to minimize experimental conduct. PAM-FORM software is used to model and simulate the thermoforming process, by studying the effects of processing parameters on the results of the simulation. The optimum thermoforming process parameters, in terms of temperature, puncher speed, puncher radius and composite thickness are determined via the design of the experiments. The output parameters, including composite thinning, shear angle and stress are analysed to identify the wrinkling defects, which are further analysed using Design-Expert software. The results demonstrate that, a temperature of 120 °C, a puncher speed of 28.78 m/s, a puncher radius and composite thickness of 4 mm and 2 mm, respectively is able to achieve minimum thinning and minimal shear angle during the thermoforming process.

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