A comparison of the machining performance of micro-electro-discharge machining (EDM) milling and sinking is proposed considering the fabrication of microchannels with controlled sloped walls realized in a hardened steel workpiece. Adopting the fine-finishing machining regime for both micro-EDM techniques, the experimental results show that micro-EDM sinking is about ten times faster than milling in the worst case, though a lack of accuracy in the final microfeatures in the former case is detected due to not compensated tool wear. On the contrary, micro-EDM milling provides a better control of the microchannel dimensions. Finally, a microfilter mold for medical applications is machined in order to show the potential of the combination of both technologies.

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