Experiments were conducted to study the effects of process parameters on surface roughness in single-point incremental forming. Decreasing step size and increasing feed rate resulted in lower surface roughness. Spindle speed had little effect on surface roughness. Additional studies found that decreasing step size while increasing tool diameter also reduced surface roughness, while feed rate and lubricant type had no significant impact. Applying heat below the glass transition temperature of polymer sheets was observed to increase formability, forming angle, and reduce forming forces.