This study investigates the optimization of process parameters for wire electric discharge machining (WEDM) of micro-complex geometries in Ti6Al4V alloy, aiming to enhance machining efficiency, accuracy, and surface integrity. The research employs a Taguchi-based design of experiments to evaluate the effects of key parameters: servo voltage (Vs), pulse on time (Ton), pulse off time (Toff), and wire speed (Ws). The results are analyzed using parametric significance analysis, surface morphological analysis via scanning electron microscopy (SEM), and modified layer analysis. The study also applies mono-objective and multi-objective optimization techniques to achieve superior accuracy and speed. Key findings indicate that Ton and Ws have the most significant influence on cutting speed and spark gap, while Vs and Toff play a crucial role in determining the accuracy index. Optimal parametric conditions of Vs = 60 V, Toff = 30 μs, Ton = 8 μs, and Ws = 6 mm/s yield a cutting speed of 3.4 mm/min, a minimum spark gap of 0.344 mm, and an accuracy index of 98.72%. The study recommends adequate flushing, reduced wire speed (economically viable), and stable spark to achieve lower spark gaps and higher accuracy. The results contribute to enhancing manufacturing efficiency, precision, and cost-effectiveness in the aeronautical industry, meeting the demand for high-quality components with tight tolerances. The findings also highlight the importance of balancing process parameters to achieve optimal performance in WEDM of micro-complex geometries.This study investigates the optimization of process parameters for wire electric discharge machining (WEDM) of micro-complex geometries in Ti6Al4V alloy, aiming to enhance machining efficiency, accuracy, and surface integrity. The research employs a Taguchi-based design of experiments to evaluate the effects of key parameters: servo voltage (Vs), pulse on time (Ton), pulse off time (Toff), and wire speed (Ws). The results are analyzed using parametric significance analysis, surface morphological analysis via scanning electron microscopy (SEM), and modified layer analysis. The study also applies mono-objective and multi-objective optimization techniques to achieve superior accuracy and speed. Key findings indicate that Ton and Ws have the most significant influence on cutting speed and spark gap, while Vs and Toff play a crucial role in determining the accuracy index. Optimal parametric conditions of Vs = 60 V, Toff = 30 μs, Ton = 8 μs, and Ws = 6 mm/s yield a cutting speed of 3.4 mm/min, a minimum spark gap of 0.344 mm, and an accuracy index of 98.72%. The study recommends adequate flushing, reduced wire speed (economically viable), and stable spark to achieve lower spark gaps and higher accuracy. The results contribute to enhancing manufacturing efficiency, precision, and cost-effectiveness in the aeronautical industry, meeting the demand for high-quality components with tight tolerances. The findings also highlight the importance of balancing process parameters to achieve optimal performance in WEDM of micro-complex geometries.