Micro-milling is a key technology in high-tech manufacturing, but improving its reliability and predictability in machining performance remains a major challenge. This comprehensive study examines the entire micro-milling landscape, integrating aspects from fundamental mechanics to practical uses, with a particular emphasis on chip formation. Also, the analysis explores into the complexities of micro-milling and illuminates machining challenges, mechanical fundamentals, machining mechanics, and the development of models for specific workpiece and tool materials. Furthermore, the review emphasizes the complexities of micro-thin wall manufacturing, given the structure sensitivity to dynamic changes, lightweight, and small scale, through a detailed examination of fabrication techniques, deformation analysis, and optimization strategies. The paper concludes with a critical discussion, identifying current limitations and outlining the path for future research, emphasizing the importance of innovations in understanding, monitoring, and refining micro-milling processes for high-precision applications.