<p>AA6061-T6 a commercial aluminum alloy used extensively in airframes, aircraft engines, marine applications, automobile sector has been formed employing single point incremental forming (SPIF) process. SPIF enables the creation of complex freeform sheet metal geometries, which otherwise requires complex manufacturing setup (dies, jigs and punches) resulting in process inflexibility, in addition to huge tooling and equipment costs. SPIF is a die-less forming process, where a sheet metal is plastically deformed to a desired shape in small increments according to a given tool path on a computer numeric controlled (CNC) machine or robotic platform. SPIF process for sheet metal is well established and has enabled flexibility in creation of symmetric, asymmetric and random shapes. SPIF also provides flexibility to tailor the surface characteristics and appearance of the formed sheet according to the application due to parametric flexibility. The current work focusses on extensive experimental parametric study on surface integrity in terms of surface roughness, surface topography, induced surface residual stresses and corresponding surface corrosion of AA6061-T6 formed sheet employing SPIF. In the study, effect of tool rotational speed, tool feed rate, incremental depth, sheet thickness, lubrication and tool interaction with sheet (in terms of sliding friction and rolling friction) on the surface integrity aspects has been presented considering varied levels. The results have indicated substantial bearing and variance in all the surface aspects at varied forming parameters and levels. The study shall provide a comprehensive overview regarding the selection of parametric levels to obtain the desired surface characteristics of the formed sheet.</p>