Disclosed are a method and system to form a contoured structure using deep rolling. The method includes using deep rolling to introduce plastic deformation to one or more portions of a work piece to form a convex contour in the work piece. The work piece, and subsequently formed contoured structure, can be metal or composite. The disclosed deep rolling systems and methods form, for example contoured aircraft panels, while also providing fatigue strength improvement and low level of work hardening during the forming process rather than as a post-production surface treatment.