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The innovative Incremental Sheet Forming (ISF) process affects the post-forming properties of thermoplastic polymers. However, the effects of degree of plastic strain, and the orientation and size of specimen on the mechanical properties are still unknown. In the present study, therefore, the ISF process is performed on a polymer sheet by varying the plastic strain ranging from 6% to 108%. The corresponding effects on the properties and associated polymer structure are quantified by conducting a variety of mechanical and structural tests. The results reveal that the post-ISF tensile properties like yield stress, ultimate stress, drawing stress, elastic modulus and elongation decrease from 26.6 to 10 MPa, 30.5 to 15.4 MPa, 18.9 to 9.9 MPa, 916 to 300 MPa and 1107% to 457%, respectively, as the strain increases in the investigated range. The value of post-ISF relaxation properties, contrary to the tensile properties, increases with increasing strain up to 62%. Particularly, reductions in stress, strain and modulus increase from 41% to 202%, 37% to 51%, and 41% to 202%. As regard the orientation effect, the sheet in the feed direction shows greater strength than the transverse direction (up to 142% in yield stress and 72% in ultimate stress). Moreover, the smaller sample offers greater strength than the larger one (up to 158% in yield stress and 109% in ultimate stress). The analysis of the post-ISF tensile properties and structural results lead us to conclude that the drop in the tensile properties due to increasing strain occurs due to corresponding increase in the voids area fraction (1.25% to 31%) and a reduction in the crystallinity (38% to 31%). [ABSTRACT FROM AUTHOR]