Micro electrical discharge machining (micro-EDM) has the advantage of being a non-contact machining technique that allows it to machine difficult-to-cut materials. Due to the absence of the typical mechanical stress present in conventional machining, micro-EDM can be used to machine high-aspect-ratio microelectrodes and use fabricated microelectrodes in drilling of high aspect ratio micro-holes in difficult-to-machine materials. The objective of this study was to explore the machining of the highest possible aspect ratio microelectrodes using micro-EDM. This study specifically focused on identifying machining strategies and parameters to produce consistent, high-quality microelectrodes with the smallest possible diameter and largest possible aspect ratios. It was found that among different techniques of microelectrode fabrication, the self-drilled technique was effective in the fabrication of high aspect ratio microelectrodes. Electrodes were fabricated using the self-drilled holes technique in which a hole is drilled in a piece of metal plate under conventional polarity (workpiece positive, tool negative), and then, the polarity is reversed to make the tool positive, thereby making it the “workpiece” and allowing the micro-EDM process to remove material from it. The electrode is then moved slightly off-center relative to the previously drilled hole, and the edge being fed into the plate is removed. This will reduce the diameter of the electrode, and the process can be repeated until the electrode has reached the desired diameter and length. All machine tools experience some sort of spindle run-out due to long microelectrodes and inherent (yet small) inconsistencies in spindle construction. In conventional machining, these minute values are typically a nonfactor, but in micro-machining they can be a large issue due to the extremely small scale of machining operations. This is why the self-drilled hole technique is better suited to small electrode fabrication than the currently common techniques, where the rotating spindle guarantees that run-out is as small of a factor as possible. The machining parameters for hole drilling were a feed rate of 0.1 mm/min, workpiece positive polarity, 110 V voltage, 10 nF capacitance, and 750 RPM of spindle rotation. The parameters for electrode dressing were a feed rate of 0.1 mm/min, electrode positive polarity, 100 V voltage, 1000 pF capacitance, and 750 RPM of spindle speed. After a number of operations, the voltage and capacitance were both reduced to accommodate the decrease in the electrode diameter. It was found that the selected parameters were successful in producing microelectrode with less than 50-micron diameter and more than 5 mm length (aspect ratio of 100+). This technique is, therefore, able to fabricate tools that can drill micro-holes at an aspect ratio that would be difficult to achieve in hard or brittle materials using conventional machining due to the cutting force associated with mechanical contact-based machining. In the current push towards miniaturization, the proposed self-drilled hole method of micro-tool fabrication could be used to produce sub-50-micron tools (less than diameter of human hair) with the ability to satisfy the niche demands of the modern manufacturing world.