Sandwich structures are gaining increase application in aeronautical, marine, automotive and civil engineering. Since such sheet can be subjected to stamping processes and their deformation limited by various defects, knowing beforehand the limiting amount of deformation is very important. For achieving this goal, sandwich sheet of Al 3105/Polymer/Al 3105 were prepared using thin film hot melt adheres. FLD of sandwich sheet was predicted using simulations by considering GTN damage model. Also FLD of prepared sheets evaluated through experimental investigations.