Micro drill-bits for halogen-free printed circuit boards were analyzed using Taguchi methods and response surface methodology (RSM). Since micro drills have many shape factors, which are not easy to describe exactly, Taguchi methods are one of the most common optimization approaches. However, Taguchi methods can only optimize among fixed variables. Using RSM, one can create a regression surface. Optimal shapes of micro drills were determined using a normalized sum of various measures of performance. It was suggested that RSM combined with other methodologies should be used with more shape factors to further analyze the performance of micro drill-bits.