The current research implements in-house built maglev-EDM with pure DC power supply to fabricate micro-holes on Ti-6Al-4V alloy using copper cylindrical rod (ø = 530 µm). Initially, a Ti-6Al-4V alloy plate of thickness 5 mm has been sliced into micro-sheets (thickness = 200 µm) using wire-EDM process. The micro-slicing operation was performed using 250 µm cutting wire electrode at feed rate of 1.12 mm/min and peak current of 12 A. The micro-sliced sheets are used as workpiece for micro-hole fabrication in maglev-EDM at a discharge voltage of 25 V and discharge current of 0.5 A using distilled water as a dielectric. The experiments are repeated thrice with discharge pulse inspection using cathode ray oscilloscope (CRO) throughout the machining time registered using stopwatch. The machining operations were performed at a duty cycle of 95% for every experimental repetition. The performance outcomes such as average hole overcut (OC), circularity error (CE), and taper angle (TA) have been acquired at a stagnant dielectric flow rate. The experimental values of specific energy, overcut, taper angle, and circularity error at the optimal parameter have been obtained as 6.20 J/µg, 12.40 µm, 3.091°, and 38.40 µm, respectively. The maglev-EDM produces a micro-hole on conductive material, from the experiment the average machining rate of 53.16 µg/min. The machined surface has been inspected using a metallurgical microscope to acquire the extended focal imaging (EFI) image of machining conditions. Furthermore, the analysis of voltage-current characteristics waveforms depicts stable and consistent pulses with negligible irregularities. It also illustrates there is stable and uniform discharge occurs leading to better energy utilization as compared to conventional systems.