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Despite several advancements in the applicability of micro‐WEDM process, the kerf‐loss and its detrimental influence on the relative accuracy and precision have remained an area to be ad‐dressed. Due to the occurrence of secondary discharges between the wire and workpiece sur‐face, the feature size is intended to be larger than the wire diameter. Therefore, the width of the feature perpendicular to the motion of wire‐travel is commonly termed as kerf‐loss. It consists of the diameter of the wire and the radial overcut on either side of the wire. The radial overcut introduces the geometric inaccuracies in the intended feature as it adds the dimension of the feature in addition to the wire diameter. Moreover, the lateral vibration of the wire which is ex‐tremely difficult to detect and prevent owing to the complex phenomenon happening in the nar‐row gap results in the increased kerf‐loss [1]. Minimization of kerf‐loss demands either reduc‐