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Resolving earlier industry recognized problems associated with two sheet SPF/DB, results in a process that will provide light weight [8], strong, corrosion and heat-resistant structures for aircraft and other applications. Solutions to the normally inherent problems of stiffening bead collapse/distortion and other associated anomalies have been resolved by utilizing gas-management methods and developing press operating techniques which removes these aesthetic and structural defects from the two sheet SPF/DB process. In addition, the design of this type of structure must be robust and consider bondline locations, weight control methods, stiffening bead definition [1] and overall producibility. Finite Element Modeling [4] has greatly assisted in better product and forming definitions prior to final design of two sheet SPF/DB structures.