<p>Forming tools can achieve efficient and high-quality processing of complex structural parts with their special shape design. However, the complex tool profile is prone to cause chip accumulation in the processing process, which increases the cutting resistance and the temperature in the cutting area, and then causes the local area of the forming cutter to wear more severely, resulting in premature failure of the forming tool. To enhance the chip removal and heat dissipation ability during the cutting process of the forming tool and reduce the cutting force, this study proposes a method for designing non-uniform edge passivation with the goal of improving cutting performance and extending tool life. Firstly, based on the passivation principle, the non-uniform edge passivation design of the cutting edge is carried out, and the non-uniform passivation model of the cutting edge is established. Secondly, through the cutting simulation experiment of the cutting edge, the influence of the edge radius on the cutting performance of the tool is clarified. Finally, the zoned optimization method of the forming cutter is proposed, the forming cutter is prepared according to the optimization result, and the cutting performance and tool life experiment of the tool are carried out through the comparative experiment. Compared with the common passivation method, the non-uniform edge passivation tool has achieved significant improvement in cutting performance and tool life.</p>