Titanium alloy Ti6Al4V has been broadly used in aerospace and biomedical devices, due to its extraordinary strength, light weight, corrosion resistance, low thermal conductivity, and biocompatibility. Micro-milling is the most flexible and promising method for fabricating miniature parts or complex micro features on titanium alloy. However, titanium alloy is difficult to machine, especially for the micro-milling process. Burr is one of the most serious problems. The dynamic interaction between tool tip and workpiece can affect the surface roughness. Process parameters such as spindle speed, feed, and depth of cut need to be optimised to achieve improved surface quality. This paper presents an experimental study to investigate the cutting forces, machined surface integrity and burr formation under different cutting conditions in micro-milling Ti6Al4V. Influences of the cutting parameters are assessed. Analysis of variance is conducted which is an efficient way to assess signification of each factor's effect.