Incremental forming is an unconventional sheet metal forming technique. It is a versatile method for the development of complex sheet metal parts using minimum tooling. The formability limit in a typical incremental sheet forming (ISF) far exceeds the conventional methods due to the inhibition of necking failure. Gradual thinning and subsequent fracture limit the process. In this work, fracture limits for AA1050 Aluminum alloy are evaluated experimentally and using FE analysis. A continuum damage approach is explored for fracture prediction in ISF. The design of the formed component and the toolpath methods greatly influence the formability. An attempt is made to understand the effect of the toolpath method and the part asymmetry on the geometric inaccuracy and the formability of the process. A methodology is also proposed to evaluate the effect of machine stiffness on the overall geometric accuracy of ISF using industrial robots.