Plasma-jet forming is a newly proposed flexible sheet metal forming process. Instead of mechanical part specific tools, a non-transferred arc plasma-torch is used to produce internal stress for forming the sheet metal. This method has the potential to reduce development cost and lead-time for forming prototype parts. In order to develop a controllable plasma-jet forming system and to improve the forming accuracy, the effects of process parameters and their relationships have been investigated. In addition, material properties have also been studied to understand the roles of forming parameters and their relationship in optimizing the forming procedure - high forming speed without material damage.