The growing demand for products made of cutting-edge materials with increased attributes motivates material scientists to investigate prospective variants of such materials. Among the various categories of life-saving advanced materials are biomaterials, although shaping most of them according to the needs encounter manufacturing constraints due to their specific mechanical properties. For example, the extremely tough alloy Ti6Al4V, is renowned for its outstanding mechanical compatibility with the human body. Nonconventional means of machining have gained popularity keeping focus on the challenging machining circumstances that are well-known for their very precision and machining accuracy, no matter what type, shape, or hardness is being machined. Electrical discharge machining (EDM), for example, is the most prevalent efficient means of material removal, along with wire EDM (WEDM), [Formula: see text]-WEDM, and so on. Excess material should be removed for more particular applications of complex and baroque shapes, with a high degree of smoothing and finish, is one of the most advantageous characteristics of wedding metal dielectric material ([Formula: see text]-WEDM). In this study, we examined the effect of variable pulse-on (Ton), pulse (Toff), time (to), flushing pressure (FP), wire feed rate (WFR), wire tension (WT), voltage (SV), and peak current (PC) on [Formula: see text]-WEDM’s reliability of the machined section (SR) using physical vapor deposition (PVD) technique to deposit aluminium nitride (TiAlN) coating on the surface of the metal. The results demonstrate a substantial reduction in roughness in the mechanically produced surfaces, further demonstrating, and confirming the biocompatibility of metals dielectric materials ([Formula: see text]-WEDM) with tissues within the human body.
