The Single-Point Incremental Forming (SPIF) is a flexible and low-cost method for manufacturing prototypes. This research investigates the influence of wall angle, vertical step size, and tool speed on two critical criteria: thickness distribution and dimensional accuracy, during the forming of thin aluminum sheets (0.1 mm). Given the minimal sheet thickness, severe thinning poses a significant challenge that can lead to premature tearing. Therefore, the goal is to optimize parameters to achieve maximum residual thickness and minimum dimensional error. For efficient optimization, the Design of Experiments (DOE) was conducted using the Taguchi statistical method and an L9 orthogonal array. Practical experiments were performed on a mini CNC machine, and the response data was analyzed using Analysis of Variance (ANOVA). ANOVA results showed that the wall angle has the most significant effect on thickness, with the vertical step size ranking second. The optimal parameter combination for the production of thin parts was determined. Furthermore, the process was simulated using a Finite Element (FE) numerical model in abaqus and validated against experimental data, which showed very good agreement for predicting thickness distribution. This study provides a comprehensive statistical-numerical approach to optimizing SPIF for ultra-thin materials.