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Conventional sheet metal forming processes require dedicated tooling and expensive dies to produce sheet metal components which make the processes time-consuming, uneconomical and inappropriate for batch type production. Incremental Sheet Forming (ISF) process is very suitable for rapid prototyping and largely decreases the tooling costs in order to form the components. Hence, multi-variety components in small batches can be manufactured at lower cost with ISF technology which prevents limitations of traditional sheet metal forming processes. This paper focuses on the investigation of process parameters like tool diameter, step size and spindle speed on the average surface roughness of formed components on AA2024-O sheets. Surface roughness has been measured by a roughness tester. Average roughness was found to increase with the decrease in tool diameter. Combination of larger tool …