This paper aims to study the influence of process parameters on the breathing zone concentration of the aerosol generated from the electrical discharge machining process using Taguchi methodology. Peak current, pulse duration, dielectric level above the spark location and flushing pressure were the process parameters considered in this work. Characterization of the components present in the aerosol and its morphology are also presented. The metallic particles present in the aerosol were analyzed using Inductively Coupled Plasma (ICP). Gas Chromatography coupled with Mass Spectrometry (GC-MS) was used to analyze the hydrocarbon components attached to the aerosol. Scanning Electron Microscopy (SEM) and X-Ray Diffraction (XRD) techniques were applied to study the morphology of aerosol. Analysis of the results showed that the peak current and the pulse duration are the most significant parameters on the breathing zone concentration of aerosol. Investigation using ICP revealed that the major portion of aerosol (about 69%) constitutes metallic particulates. GC-MS analysis of the aerosol samples indicated the presence of about 20 different hydrocarbons. Morphology studies showed that the particulates are of spherical shape with average sizes ranging from 20 to 29 nm. The control measures to minimize the risk of exposure have also been discussed in this paper. (C) 2010 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.