“…Thin metal sheet micro-forming process, well-known for their process simplicity, high production rate, minimized material waste, near-net-shapes, excellent mechanical properties [1,2], and close tolerances [3], are claimed to be the most suitable process to fabricate micro-parts in the fields of electronics [4], medical devices, Micro Electro Mechanical Systems (MEMS) [5], and Micro System Technology (MST) [6 -10]. However, there are challenges in the thin metal sheet forming process when the sheet thickness is decreased to the level of micrometres, because of the unknown deformation mechanics and material behaviour which called the "second order size effect" [11 -15].…”