Abstract: Products used in critical industries like aerospace, automotive and power plant require specific and critical limits of the mechanical properties. In aircraft a very slight deviation from required specifications may result in the loss of both lives and equipment’s. One of the important materials used in aerospace, automotive and electrical power industries is AISI 3115, it is used in structural components, heat exchangers, electrical resistance applications such as dynamic braking and overload resistors and etc. Through the Electrical Discharge Machining (EDM) process of the material AISI 3115, mechanical properties can be affected, these effects cause the product performance degradation and can lead to failure of the products in industry. Most of research done on EDM process optimization, focused on same traditional process responses such as (surface roughness, material removal rate, tool wear). It is likely not enough work has been done on how to optimize and reduce the change in product mechanical properties its self such as (generating residual stress, decreasing hardness, decreasing flexure strength, degradation of fatigue strength, affecting the fracture toughness, reduction in corrosion resistance). Also, it has been noted from literature review that no work has been done for optimization of both process responses and nor the mechanical properties of the AISI 3115 material during the EDM manufacturing process. The aim of this research is to discuss and propose the use of metaheuristic algorithms and propose using new electrode material to optimize the mechanical properties of AISI 3115 and to minimize and eliminate product failures in industry due to degradation of mechanical properties.