The present study aims to precisely manufacture the turbine wheel slot using a novel trim-offset approach of wire-electrical-discharge-machining (WEDM) in order to overcome the challenges of a conventional broaching process. Two dimensional model of turbine wheel slot is prepared in ‘ELCAM’ software to generate the computer-numerical-control (CNC) code of fir-tree-profile geometry. The experimental plan based on a trim-offset approach is executed to minimize the thermal damage and to improve the surface fatigue strength, which is most desirable for a long operating life of the jet engine. An average cutting speed of ~1.5 mm/min is observed for rough-cut and ~5 mm/min for trim-cut operation. Six categories of wires are used to manufacture the turbine wheel slots without any wire breakage and gap-short issue. The fabricated profile slots have demonstrated an average roughness (Ra) of 0.65 μm, profile accuracy within ±5 μm, minimum hardness alteration (34.87 Hv), and negligible recast layer (<5 μm) using B-150 wire and fulfilled the essential requirements of the gas turbine industries. Compared to wire-electrochemical-machining (WECM), WEDM trim-offset approach is quite advantageous and should be beneficial for the researchers working in ‘Precision machining of aerospace materials’. © 2021 Elsevier Inc.