Thermoplastic composites (TPCs) are increasingly adopted in next-generation aircraft structures due to their short cycle times and improved sustainability. In press-based stamp forming, however, achieving tight dimensional tolerances remains challenging because non-uniform heating and cooling, crystallization during consolidation, and mold–laminate contact conditions jointly generate residual stresses. Upon demolding, these stresses are released as process-induced deformation (PID), typically manifested as spring-in, warpage, and local angle deviations. In practice, spatially varying pressure and contact in rigid metallic tooling can further amplify these deviations, even when the forming cycle appears stable. In this talk, we present a finite element framework that links thermal history and crystallization state to the final geometry after demolding. Implemented in ABAQUS through user subroutines, the model consistently accounts for crystallinity evolution with rate dependence, crystallization heat release, anisotropic thermal expansion, and temperature- and crystallinity-dependent mechanical response. The approach is demonstrated on several stiffened aerospace components. Tooling pressure distribution and contact conditions are characterized and related to the resulting deformation patterns. Predictions are validated against measured part geometries, and we conclude with a practical workflow to define robust process windows and tool-compensation targets, reducing rework and improving tolerance achievement in high-rate manufacturing.