As industry evolves, many studies on metal processing are conducted. Among them, the method to design the shape of forming roll of roll forming process still relies heavily on experimental and trial and error methods. This study suggested a systematic and effective design method in order to shorten the development time of forming roll by using a flower design method. Also, it suggested 3D-based forming roll shape design techniques that considered flowers’s volume unlike the 2D-based flower design method usually applied inthe existing studies. And in order to examine the validity of the suggested shape design method, it predicted the strains of the complicated shape based on the suggested flower design method and cross-checked the results with the actual product shape.