The single-point incremental forming (SPIF) technique is an innovative method for sheet metal processing, whereby a sheet blank is firmly clamped at its edge while a single-point tool gradually deforms it along a predetermined trajectory in successive downward increments. This method provides three-dimensional sculpting without using dies. Surface roughness and non-uniform thickness distribution provide significant challenges in the parts formed by using SPIF process, highlighting the essential need to study the effect of forming parameters on these characteristics throughout the process. The present work adopts a systematic approach to determine the combined effects of tool diameter, feed rate, and tool rotating speed in controlling surface roughness and material thinning. The investigation conducts experiments on AA 1200 aluminum alloy followed by Taguchi technique and variance analysis data evaluation. The study reveals which processing variables allow for maximum surface finish reduction along with increased material thickness which leads to better manufacturing performance and product quality.