This study investigates the optimization and performance analysis of wire electric discharge machining (WEDM) for micro-complex geometry machining of Ti6Al4V, a high-performance alloy used in aeronautical and biomedical industries. The research focuses on evaluating the potential of WEDM for fabricating complex geometries, addressing the challenges of stack-up tolerances and the limitations of conventional machining processes. A Taguchi-based design of experiments is employed to study the effects of process parameters such as servo voltage (V_s), pulse on time (T_on), pulse off time (T_off), and wire speed (W_s). The results are analyzed through parametric significance analysis, parametric control analysis, surface morphological analysis using scanning electron microscopy, and modified layer analysis. Both mono-objective and multi-objective optimization techniques are used to achieve superior accuracy and speed. The findings indicate that T_on and W_s have the most significant influence on cutting speed and spark gap, while V_s and T_off play a crucial role in determining the accuracy index. Adequate flushing, reduced wire speed, and stable spark are recommended to attain a lower spark gap and higher accuracy. The optimal parametric conditions, V_s = 60 V, T_off = 30 μs, T_on = 8 μs, and W_s = 6 mm/s, provide the highest cutting speed of 3.4 mm/min, a minimum spark gap of 0.344 mm, and an accuracy index of 98.72%. The research contributes to enhancing manufacturing efficiency, precision, and cost-effectiveness in the aeronautical and biomedical industries, meeting the demand for high-quality components with tight tolerances.This study investigates the optimization and performance analysis of wire electric discharge machining (WEDM) for micro-complex geometry machining of Ti6Al4V, a high-performance alloy used in aeronautical and biomedical industries. The research focuses on evaluating the potential of WEDM for fabricating complex geometries, addressing the challenges of stack-up tolerances and the limitations of conventional machining processes. A Taguchi-based design of experiments is employed to study the effects of process parameters such as servo voltage (V_s), pulse on time (T_on), pulse off time (T_off), and wire speed (W_s). The results are analyzed through parametric significance analysis, parametric control analysis, surface morphological analysis using scanning electron microscopy, and modified layer analysis. Both mono-objective and multi-objective optimization techniques are used to achieve superior accuracy and speed. The findings indicate that T_on and W_s have the most significant influence on cutting speed and spark gap, while V_s and T_off play a crucial role in determining the accuracy index. Adequate flushing, reduced wire speed, and stable spark are recommended to attain a lower spark gap and higher accuracy. The optimal parametric conditions, V_s = 60 V, T_off = 30 μs, T_on = 8 μs, and W_s = 6 mm/s, provide the highest cutting speed of 3.4 mm/min, a minimum spark gap of 0.344 mm, and an accuracy index of 98.72%. The research contributes to enhancing manufacturing efficiency, precision, and cost-effectiveness in the aeronautical and biomedical industries, meeting the demand for high-quality components with tight tolerances.