The isothermal forging design of a Ti-6Al-4V wing shape was performed by 3D FE simulation. The design focuses on near-net shape forming by the single stage. The process variables such as the die design, pre-form shape and size, ram speed and forging temperature were investigated. The main design priorities were to minimize forging loads and to distribute strain uniformly in a given forging condition. The FE simulation results for the final process design were compared with the isothermal forging tests. The instability of deformation was evaluated using a processing map based on the dynamic materials model(DMM), including flow stability criteria. Finally, a modified process design for producing a uniform Ti-6Al-4V wing product without forming defects was suggested.