In this paper, Electrical Discharge Machining (EDM) over Ti-6Al-4 V investigated while employing aluminum oxide/alumina (Al2O3) powders-mixed EDM oil as dielectric fluids. Alumina powder underwent analysis for microstructure and size using scanning electron microscopy (SEM). Results confirmed the spherical microstructure which has an average diameter of 10 μm. Experimental design uses DOE-Taguchi L9 orthogonal array with three machining parameters namely, concentration (2–4 g/L), voltage (40–60 V), and current (1–2 A) to evaluate the prime machinability performances like MRR and TWR. Main effects plot for data means and ANOVA according to the mono-objective optimization technique (Taguchi analysis) highlights the effect of input/process parameters on output/machining characteristics. Results discovered that the concentration: 4 g/L, voltage: 60 V, and current: 2 A have produced higher MRR during PMEDM of Ti-6Al-4 V for drilling micro-holes. Also, lower TWR has been achieved by optimal process parameters such as: concentration: 2 g/L, voltage: 40 V, and current: 1 A. This paper work has also explored the utilization of negative polarity to obtain better machinability compared to other typical EDM process. The use of dielectrics with aluminum oxide powders proved better machining stability and improved surface topography, as confirmed by SEM images at significant PMEDM setting. The research work findings show that the PMEDM utilizing alumina additives yields crack-free, smooth surfaces, and minimize recast layer thickness. Thus, this promising work is widely applied in demanding micro manufacturing sectors, especially aerospace, chemical, electronics, bio-medical, and medical fields, due to its excellent properties.