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This study presents the development and application of a thin BD-PCD (Boron-Doped Polycrystalline Composite Diamond) wheel-tool t hat combines reverse RWEDM (Rotary Wire Electrical Discharge Machining) with HSFSG (High-Speed & Fast-Shallow Grinding) for directly generating precision microgrooves onto NAK80 mold steel.The good electrical conductivity of BD-PCD allows for a thin grinding-edge of 5-mm thickness to be produced.The HSFSG technique is used to successfully grind micro-grooves in NAK80 mold steel.The proposed method overcomes the traditional obstacles when using diamond to machine steel by excellent metal removal rates.Experimental results prove the precision of the microgrooves generated.A biochip-mold, possessing micro checkerboard-like layout, is successfully machined by the developed machine tool, the BD-PCD wheel-tool and the designed process.The factors influencing formability, graphitizing of the BD-PCD tool and the accuracy of microgroove are discussed in detail.