Among various methods to manufacture the PDP barrier ribs, the pressing and the roll forming methods are simple and economical because they form the ribs by utilizing the plastic flow of the green tape in a relatively short time without generating air-polluting dusts. In the present study, the roll forming method was investigated by experiments as well as numerical analyses and in result the groove roll and the preform were designed. The effect of draft angle, corner radius, and initial thickness of the green tape on the plastic flow was examined by a series of parametric studies. The preform was recommended to ease the plastic flow into the grooves and to avoid the occurrence of cracks during rolling and sintering processes.