Many process design factors effect the outcome of a sheet stamping operation. Particularly inner panel structures of hang-on panels are difficult to produce in aluminium. This paper deals with material behaviour issues related to formability and friction.Formability is characterized by the mechanical properties while friction is related to surface topography. Formability is evaluated by means of laboratory tests and stamping trials on actual inner panels. Optimum results are obtained with materials with high n value and isotropic r value. An improved AA5182 alloy has been developed to meet these demands on mechanical properties. This alloy creates the best condition for downgauging and cost saving targets.