Summary: A new initial solution estimation method for inverse finite element approach is proposed in this paper. One of the inverse finite element approach’s advantages is that it can rapidly predict the formability of final parts and initial blank profile during the early design phase, but there usually exist many flange and concave areas on the final parts. At present, quite a number of initial guess methods are based on projection algorithms and they are helpless for these undercut issues. In order to deal with the overlap issues, a new initial guess estimation method is considered based on an energy model that has proven to be robust and efficient when dealing with these issues. A dynamic explicit algorithm is used to solve this energy model; the main difficulties of implementing this algorithm are focused on the computing time due to the iteration feature of the dynamic explicit method. In order to deal with this difficulty, the flow of the algorithm getting initial position of the energy-based deformable model is revised according to Saint-Venant’s principle to obtain a more precise initial position, which has proven to improve the convergence speed of iteration. Furthermore, due to dealing with the undercut issues, the new initial solution estimation method also helps in the successful application of the inverse finite element method to the progressive die field.