In order to improve automotive fuel economy, vehicle weight should be reduced. Achieving significant weight reductions will normally require reducing the panel thickness or using alternative materials such as aluminum alloy sheet. These changes will affect the dent resistance of the panel. In this study, the correlation between panel size, curvature, thickness, material properties and dent resistance is investigated. A parametric approach is adopted, utilizing a "design software" tool incorporating empirical equations to predict denting and panel stiffness for simplified panels. The most effective period to optimize an automotive body panel is early in its development. The developed design program can be used to minimize panel thickness or compare different materials, while maintaining adequate panel performance.