Machining of high aspect ratio micro-channels and cavities in metals is a challenging task. Micro-electrical discharge milling is a version of micro-electrical discharge machining process which is capable of micro-machining of all electrically conductive materials. The aim of this study is to analyze the effects of non-electrical parameters such as layer thickness (LT), horizontal tool feed rate (HTF), and tool rotational speed (TRS) on material removal rate (MRR) and relative electrode wear (REW) while micro-electrical discharge (μED) milling of stainless steel using tungsten electrode. The study revealed that layer thickness along with tool rotational speed and horizontal feed rate of the tool significantly influences the performance of μED milling. © 2015, Springer-Verlag London.