The production and use of micro-parts has become more widely used in many industries such as electronics, computers, micro motors, and micro surgical instruments. Metal forming processes are one of the production methods of this group of parts due to their high accuracy and mass production capability. These processes often face several challenges. Due to the wide range of applications of micro-components and the use of micro-gears in the watchmaking industries, this work was devoted to design and manufacture micro-gear from AA-1100 aluminum alloy using backward extrusion method to overcome the challenges of manufacturing and production to produce a gear with micro dimensions. In this research, a backward micro extrusion die was made to produce a micro gear with a clock-type tooth profile. The backward extrusion process was simulated using Deform_3D finite element commercial package and the parameters such as forming force, extruded velocity, stress and strain distribution within the workpiece were obtained for the next steps. The extrusion die with all its components was designed to predict the output of the final part and design the die mechanism. After design, the die was fabricated and assembled step by step in order of manufacturing priorities. At first, the die was tested to control and check how it works properly. Finally, an experiment was designed and performed to evaluate the dimensional accuracy and quality of the surface of the gear, in dry state (without lubricant), with oil and with solid zinc phosphate lubricant, at two speeds of 2.5 and 5 mm/s. The extruded gears were examined using a video measuring machine. The result showed that the extruded gear is more accurate in terms of dimensional accuracy gear (drawing size), in the case of zinc phosphate, than oil and without lubricant. These dimensions were produced and measured in a zinc phosphate solid lubricant test at a ram speed of 5 mm/s with maximum tolerances of 0.01 mm in outer diameter, 0.003 mm in tooth head diameter, and 0.005 mm in tooth thickness. In samples tested without lubricant, surface and edge distortion was observed, these defects were reduced in samples extruded with oil lubricant and in sample with zinc phosphate lubricant no surface and edge distortion was observed. Keywords: Micro Forming, Micro Backward Extrusion, Micro-Gear