This present work deals with the features of trim cut wire EDM machining of Nimonic 80A in terms of machining parameters, to predict material removal rate (MRR), surface roughness (Ra), wire wear ratio (WWR) and microstructure analysis. Trim cut is performed after rough cut to remove the rough layer deposited after machining due to melting and re-solidification of the eroded metal from workpiece as well as from wire electrode. Taguchi’s design of experiments methodology has been used for planning and designing the experiments. The relative significance of various factors has also been evaluated and analyzed using ANOVA. The results clearly indicate trim cut potential for high surface finish compared to rough cut machining.