The single point incremental sheet forming method includes characteristics that can adapt to a wide range of applications and needs. Incremental forming might have undesirable quality if process parameters are not properly set. A simulation software ABAQUS was used to perform single point incremental forming of polyamide 6 by varying parameters such as tool rotational velocity, feed rate, feed per revolution, and wall angle to investigate their influence on the thickness thinning and geometric accuracy of the formed component. Experimentation was performed using a 3-Axis Numerical Control Milling Machine to study the different defects occurring throughout the process. The investigation was performed on a 100 mm × 100 mm flat polyamide-6 plates. Taguchi L9 orthogonal array was adopted to evaluate minimum number of iterations essential for computing supremacy of forming parameters on minimum thickness achieved from the fabricated component. The geometries obtained from simulation and by experiments were compared for final thickness, depth, and wall angle. Maximum thickness and depth that can be achieved was found out to be 0.71 mm and 18.52 mm respectively through experimentation. The wall angle achieved with experimentation was found to be increased with an average of 1.76° when compared to desired geometry. A coordinate measurement machine was used to obtain the profile of the formed geometry. It has been observed that, the wall angle was the most dominant parameter that affects the thickness thinning, followed by the feed rate of feed, feed per revolution and spindle speed. There is need to create multi-stage solutions for improving formation limits. This will help to maximise the forming window by utilising consistent thinning. © 2022