Miniaturization of the products is a field of interest that includes several conventional to advanced micro-manufacturing processes. Micro-forming is one of the processes among the other micro-manufacturing process, which is a well-suited technology capable of producing small metallic parts with better material properties. However, several limitations are required to be addressed. Present research work is focused on addressing the limitation of tool design for the tools used in forming process. In current work, a patterned tool is used to fabricate form-tools, using an Electric discharge machining process, which can be used in the micro-forming process. Machining involves the thermal energy transfer, which in turn alters the surface characteristics; therefore, surface roughness obtained after the machining process has been analyzed using the OFAT approach. Gap voltage (G_v), peak current (P_k), pulse-on (T_on), and pulse-off time (T_off) are considered for the analysis over the response, i.e. average surface roughness (R_a). Different patterns viz. Diamond and circular shapes were considered for study along with the design of the Tesla T45A single valve to analyze the applicability of the developed process to fabricate form tools with desired geometry. All the patterns were successfully obtained over the Inconel 718 alloy work material used in the present work.