Deformation machining (DM) is a combination of thin structure machining and single-point incremental forming/bending (SPIF/SPIB). This process enables the creation of complex structures and geometries, which are probably difficult or sometimes impossible to manufacture employing conventional manufacturing techniques. Geometrical discrepancies in thin structure or sheet metal bending and forming are a major obstacle in manufacturing quality components. These discrepancies are more prevalent and complex in nature in incremental or generative manufacturing. In the present work, a comprehensive experimental and numerical study on the parametric effects on various geometrical inaccuracies in DM process has been performed. This study would help in giving an insight in providing necessary geometrical compensation, ensuring a quality product over a wide range of process parameters.

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