This research introduces process innovations in Incremental Sheet Forming (ISF) that enable functional surface texturing, controlled morphing, and reconfigurable mold fabrication. By leveraging standard tools and digitally generated toolpaths, ISF is transformed into a versatile, rapid manufacturing platform with applications in marine, morphable, and molding systems. The first part explores surface texturing strategies. In Task 1, Double-sided Incremental Forming (DSIF) is used to create riblet-like textures for drag reduction and anti-biofouling on curved shell structures, such as unmanned underwater vehicle (UUV) hulls. A two-step toolpath strategy decouples global shape formation from texture alignment. Although grooves alone may increase drag, their combination with a SLIPS (Slippery Liquid Infused Porous Surfaces) coating significantly lowers drag and resists fouling. Experiments in a custom water flume validate these findings. Task 2 investigates texture-driven enhancement of SLIPS coating durability. Textures are applied to flat benchmark geometries with varying spacing, pattern types, and tool movements. Discretized dimples outperform continuous grooves by retaining lubricant more effectively and supporting self-healing. Low-speed tool spinning further improves performance by creating wavy textures that reduce contact line pinning and improve coating adherence. Task 3 presents a texture-induced morphing approach, where residual plastic strain patterns guide controlled shape changes. Finite element simulations and a reduced eigenstrain model are used to predict deformation, with experimental validation confirming agreement. This method provides a material-efficient alternative to traditional morphing systems, suitable for deployable or lightweight applications. The second part of the research focuses on ISF-based mold liner fabrication. Traditional mold-making is costly and time-intensive; here, ISF forms customized metal liners with integrated gates, vents, and textures. Liners are supported with plaster backing and assembled using reusable modular components. A modified Two-point Incremental Forming (TPIF) method enables finer resolution for small features such as embossed characters. Texture transfer to molded parts is also explored, demonstrating functional surface replication. The final part introduces a machine-learning-based toolpath planning method using MeshCNN, which segments 3D geometries based on local features. Unlike traditional z-slicing, this approach adapts toolpaths to feature shape and orientation, improving forming accuracy. The system also considers material thinning and sequencing, allowing optimized multi-feature fabrication. Collectively, this work redefines the capabilities of ISF, establishing it as a flexible, digitally adaptive process for creating multi-functional components. Through the integration of simulation, machine learning, and experimental validation, the research offers scalable, accessible solutions for advanced forming applications.