Micro-Electrical Discharge Machining for the Fabrication of Functional Surface Texture

Abstract Microscale surface textures (e.g., microgrooves, dimples, pillars) play a crucial role in tribology, optics, biomedical devices, and micro-electro-mechanical systems. Among various microfabrication technologies, micro-electrical discharge machining (micro-EDM) stands out as a cost-effective method for the fabrication of these surface textures with high accuracy. However, despite the rapid advancements in this field in recent years, a comprehensive and targeted review of micro-EDM for functional surface texturing is currently lacking in the literature. To address this gap, this paper systematically reviews recent progress in micro-EDM texturing across four major application areas: cutting tools, bioimplants, surgical instruments and mold components. For each field of application, the functional mechanisms, achievable surface features, demonstrated performance improvements, and existing technical challenges of micro-EDM are critically discussed and analyzed. Furthermore, current limitations and recommended future research directions are elaborated. This review provides valuable insights and practical guidance for advancing micro-EDM surface texturing and offers a roadmap for its broader adoption in industrial applications.