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1. The practicality of R-Electrical Discharge Machining process in the construction of organized structures of ? 3 mm and height 2 mm on mild steel has been inspected using response surface methodology (RSM) based investigation. Effect of control variables such as peak current (Ip), pulse-on time (Ton) and flushing pressure (Fp) on some of the vital geometric characteristics like taper and cylindricity error along with material removal rate (MRR), surface roughness (SR), micro hardness, surface morphology of pillared structure has been investigated. Analysis of variance (ANOVA) consequences demonstration that peak current (Ip) has important effect followed by pulse on time MRR. Peak current has important influence near Surface Roughness, taper and cylindricity error. High micro hardness was found in heat affected zone.