a method of forming an aircraft nacelle nose lip segment . the method includes bending a sheet of metal into a substantially u - shaped workpiece having a spanwise axis , opposed first and second ends , and opposed first and second edges . the method further includes placing the workpiece over a substantially flexible first mandrel , stretching the workpiece in a spanwise direction between the first and second ends , and wrapping the workpiece and first mandrel together about a curved die while stretching the workpiece . the workpiece is thereby plastically deformed to have a first shape . the method may further include removing the workpiece from the first mandrel , and placing the workpiece over a substantially rigid second mandrel that substantially corresponds in shape to the first shape of the workpiece . the workpiece is stretched over the second mandrel in a chordwise direction that is substantially transverse to the spanwise axis of the workpiece , thereby further plastically deforming the workpiece .