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This paper concentrates on the forming of a hollow wide-chord titanium fan blade with complex geometries by a more efficient and simple way. A new two-layer process based on hot forming and diffusion bonding is developed. An essential approach for optimal blank design is proposed. The presented process employed a more reliable and controllable method to construct the internal ribbons, instead of the complicated superplastic forming in contemporary multi-layer approaches. To evaluate the practicability, the numerical method is used to investigate the thickness uniformity, structural integrity and skin defects of forming results by ABAQUS. A series of experiments were conducted to validate the simulation results. The Ti-6Al-4V alloy was adopted as the forming material, and blanks optimal designed by the proposed approach were used. The scaled-down version of the hollow wide-chord fan blade was successfully formed without defects. In addition, it is observed that the experimentation and simulation agree well.