A design methodology is applied to manufacturing a disk-brake piston component. A rigid plastic finite element method is applied to simulate the conventional four-stage manufacturing process and the one-step process from a selected stock to the final product shape for information on metal flows. Two-stage forming operations with different punch comer and nose radii are also simulated to identify the best possible solutions. The best manufacturing process is selected, which uses a hemispherical punch in the drawing process. Experiments are conducted for comparison with the numerical results. The good agreement between the experimental and numerical results validates the design methodology using the finite element method.