Bulge forming (BF) processes as a metal working operation has received comprehensive investigation. The process and its products have been widely used in many areas. However, there are few papers published to deal with plastic BF (the application of BF technique to polymer processing, PBF). Compared to conventional polymer processing such as extrusion, injection moulding and blow moulding processes, the PBF process is relatively new, and therefore, there is no extensive knowledge base for tool and process design. This paper reviews the progress and features of the BF process and discusses the feasibility and necessity of PBF. In addition, the relationship between process variables and achievable part geometry and mechanical performance are investigated.