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Thermal Acoustic Protective Shields (TAPS) serves dual purpose. They provide a thermal barrier, which protects sensitive components from the exhaust manifold radiated energy. They also act as an acoustic insulator, which reduces the amount of sound power transmitted from the engine to the environment. The design of multi layered TAPS has, until recently, relied on trial and error or simplified numerical analyses. The following work describes efforts to develop a comprehensive numerical methodology for the initial forming of the components, which accounts for most of the physics of the problem. The simulation accounts for the complete forming operations of the part, i.e. edge folding, multi layer assembly, edge crimping, beading, and final forming. Non-linear effects are accounted for such as interlayer frictional dissipation, plastic anisotropy and self-contact.