This document analyzes micro-milling of hardened H13 steel. It describes experiments using different milling conditions and tool wear progression over multiple tools. Acoustic emission sensors were used to monitor the milling process. Dimensional errors of less than 1% were achieved. Finite element models were developed to simulate chip formation and heat transfer during milling, showing increased temperatures and forces with smaller tool edge radii. The simulations also indicated a build-up edge would form more often as the tool wore.