The present investigation highlights an experimental study and optimization of machining outcomes characteristics (such as MRR and Ra) during WEDM process of Inconel 625. The present work examined the effects of wire electrode materials, such as Zn-coated brass electrode (ZCBE) and uncoated brass electrode (UBE) on work material during WEDM process. Based on L16 orthogonal array, the experiment was performed in consideration with four process factor: spark-on time (Son), flushing pressure (Pf), wire-tension (Tw), and discharge current (Dc), within selected experimental domain. The additional objective of present investigation is to develop a multi-response optimization tool for selection of satisfactory process parameter setting during WEDM of Inconel 625. Nonlinear regression model was applied to formulate statistical models for multi-objective optimization using, fuzzy inference system (FIS) combination with TLBO for fulfill this objective. Finally, the satisfactory process parameter obtained by TLBO was compared with the genetic algorithm (GA) individually and found out that, the TLBO algorithm was found to be simpler, effective, and time-saving approach while solving multi-objective problems. © 2020, Springer Nature Singapore Pte Ltd.