<p>The wear of the tool is a serious concern for electro-erosive cutting process which is a commonly used procedure for producing intricate profiles in difficult-to-machine alloy like Ti6Al4V. This issue not only increases the tooling cost which primarily governs the processing cost but also compromises the dimensional consistency of the machined impression. The frequent application of traditional dielectric (kerosene) in this methodology is another criticism which questions its use. In the context, a novel blend of nanoplatelets-based rice bran oil (RBO) has been researched as substitute to conventional dielectric. However, the aspect of wear of the tool and corresponding dimensional deviation has not been comprehensively investigated so far. Specifically, the detailed analysis of the issues against a broad set of six input variables to provide a holistic view of the issues has not been reported yet. Therefore, this work is aimed to tune that process for reducing the problems of tool wear and dimensional inaccuracy along with a conscious effort to mitigate the environmental concerns. Experimentation is carried out under Taguchi’s L18 array considering six control variables. The findings have been thoroughly explained on the basis of process physics and microscopic examination of the machined cavity. The electrode of copper has proved to the best choice for reducing the tool wear and dimensional error in electric discharge cutting of Ti6Al4V using nanoplatelets mixed RBO. The values of tool wear and overcut have been reduced by 70.10% and 56.12%, respectively, if RBO is used instead of kerosene. The proposed optimized combination of control variables provides a significant reduction in the values of TWR and OC by 80.74% and 80.7%, correspondingly with respect to the mean value of responses achieved during whole experimentation. These findings not only decrease the tooling cost and dimensional errors but also contribute to make the process sustainable.</p>