EDM is a conventionally used non-conventional technique that uses sparks to precisely remove the material, making it ideal for intricate designs and it also tackles tough metals and delicate parts that wouldn’t survive traditional methods. The surface quality of AISI D2 tool steel machined using Electrical Discharge Machining (EDM) is significantly influenced by a multitude of input variables. To attain optimal surface finish, it is imperative to carefully select and adjust these machining parameters. This study employs a desirability function analysis approach, coupled with an L16 orthogonal array design, to optimize surface roughness during EDM of AISI D2 steel. An analysis of five process control variables, including voltage, current, pulse on time, duty factor, and flushing pressure, was conducted to evaluate their impact on three surface roughness parameters: Ra, Rq, and Rz. The results indicate that pulse on time and current exert the most significant influence on overall surface roughness. Moreover, the surface parameters Ra and Rq are primarily affected by pulse on time, while Rz is most sensitive to current variations.