Abstarct: Single point incremental (SPIF) forming is considered as a new method for rapid fabrication of sheet parts mextal parts, requiring no tooling nor expensive facilities. Due to lower cost and higher speed, this technique is used for fabrication of complex sheet parts prototypes. One of the important issues associated with SPIF is controlling the thinning of sheet mextal. Using finite element (FE) simulations and experimental method, this dissertation investigates the effect of five different tool path strategies on the wall thickness and height in incremental hole flanging of sheets of aluminum alloys AA1060 and AA3105. Thickness distribution and flange height obtained from FE analysis using toll pass strategies including cylindrical helix and conical helices with constant and variable baxse diameters, at constant forming speed, show acceptable correlation with the corresponding experimental results reported in the literature. Next, two novel tool path strategies which are baxsed on exponential helix, were used in the analyses and experiments. The results show that employing these two new strategies, the formability of the sheet can be increased, namely, at constant forming speed, the thickness distribution improves by 25%. Further, assessment of the FE simulation and experiment results obtained for constant and variable forming speeds, reveal that a constant forming speed results in a more uniform thickness distribution. In addition, study on the effect of tool diameter in incremental hole flanging, shows that with increasing the tool diameter more uniform thickness distribution is achieved.