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In the past decades, wire electrochemical machining (Wire-ECM) has been extensively investigated for machining flat surfaces on varying engineering materials. In the present work, an attempt has been made to develop a novel technique (mask-less as well as through-mask) for generating macro as well as micro thread profiles on cylindrical rotating shafts using wire electrochemical turning process (Wire-ECTrg). Profiles with rounded edges like British Standard Whitworth (BSW) thread profile (Thread angle 55) are fabricated using the mask-less method. Typical thread profiles are characterized and the impact of various input parameters on two key profile features, thread depth and thread angle are investigated. Generation of ball-full radius thread profile is very cumbersome to make through conventional turning process as it also requires a complex profiled tool. This type of thread profile is machined using the …