Structural pipe frames are usually manufactured by complex processes, in which a straight pipe with an arbitrary crosssection is prepared via a roll-forming process and then fabricated into three-dimensional shapes by a secondary process. These conventional processes have low productivity. Recently, the inefficiency of the conventional processes has created the need to develop new forming technologies. In this study, a new incremental roll-forming process is proposed. The study is aimed at verifying the feasibility of the proposed process and investigating the fundamental process parameters using finite-element simulations. The result of the simulation demonstrates that the proposed process can be used effectively for cold fabrication of various shapes of structural pipes. In addition, the result of the investigation of parameters shows that the forming amount, number of roll sets, and distance between roll sets are significant factors to be considered in resolving dimensional errors of the product and improving its quality.