This paper addresses the issues involved in the successful application of micro EDM for micro freeform machining. Types of Micro EDM tool wear and strategies required to reduce the inaccuracy caused by tool wear are explained. Experimental investigation of the various factors affecting the tool tip geometry and spark gap was carried out and results are presented. It is realized that a flat tool tip can be retained when a higher tool electrode size with lower depth of cut was used. When the depth of cut is equal to the tool diameter, spherical tool tip is obtained. Higher depth of cut yields conically shaped tool tip. Lower discharge energy and depth of cut minimizes the spark gap. As a step towards freeform machining, a complex micro structure having flat, spherical and tapered surfaces was machined by micro EDM using uniform tool shape method. It was found that resulting dimensions are within 10 μm deviation from the design specification.