In the midst of a huge demand for high-precision miniaturized medical implants made up of potential biomaterials, the biomedical Ti-6Al-4V alloy meets the uncompromising standards for longevity, biocompatibility, and sterilizability required to interact with living cells in medical settings. This research tailored the existing capabilities of a traditional micro-electric discharge machining (µ-EDM) setup by adding 0, 2, 4, 6, 8, and 10 g/l bioactive zinc powder particle concentrations (PPCs) to the dielectric. A copper and brass micro-tool electrode (C-µ-TE and B-µ-TE) was employed in association with each PPC. Experiments were executed using the one-variable-at-a-time (OVAT) approach. Machining time and dimensional deviation were chosen as the response variables of Zn powder mixed-micro-EDM (Zn-PM-µ-EDM). According to the analytical findings, the combination of C-µ-TE and 6 g/l Zn PPC achieved 23.52%, 3.29%, and 17.96% lesser machining time, dimensional deviation, and recast layer thickness, respectively, compared to the B-µ-TE. The detailed study of this surface endorsed a significant modification in terms of improved recast layer thickness (26.44 µm), topography (Ra = 743.65 nm), and wettability (contact angle < 90 deg), suggesting its dental application. In addition, the observation of ZnO and TiO in X-ray diffraction and appealing in vitro cytocompatibility encourage the subsequent biological and therapeutic studies to validate the anticipated antiviral activity of the modified Ti-6Al-4V alloy surface against coronavirus (COVID-19).