The material melted and quickly solidified on the surface, forming a Recast layer over the machined surface. The present experimental assessment measures the extent of influence of machine variables towards the deposition of recast material post-machining Die Steel D3. The microstructure of the recast layer is dendritic and columnar due to sudden quenching, causing complex phase transformation. Scanning Electron Microscopy is utilized to assess the range of recast deposition. The range of average recast deposition is between 32.7 to 68.5 µm. The sequential model and lack of fit tests depict that the EDM parameters and recast layer can be modeled using 2FI equations. The analysis apprised that peak current (p-value < 0.0001) has a crucial impact on recast deposition. The duration (p-value = 0.4694) was the minimal affecting factor amid selected variables for white layer thickness, which aligns with the previous literature. The impact of current and duration is almost linear towards recast layer thickness and higher deposits of recast layer (RL) are observed at higher levels of current and duration. Lower RL can only be attained by setting a lower current and on duration. The influence of lower voltage is not much on recast layer thickness at minimum value of peak current. The residual error of 3.13% during model validation illustrates the adequacy of the model.