Ultra-precision machining of optical components requires sharp cutting tools. Since crystal diamond are often used as cutting tools since they are available in bulk form, are hard, and can be sharpened to tens of nanometers with a smooth uniform cutting edge shape. However, there are a few ceramic single crystals although not as hard as diamond but are significantly harder than the non-ferrous workpiece materials that optical components are made of. Single crystal alumina (Sapphire) is one such crystal with a hardness of 22 GPa and is available in bulk form. In addition, it has high wear resistance and chemical inertness and hence, can be a suitable alternate single crystal tool material. This study investigates the use of sapphire as a cutting tool for ultra-precision machining and discusses fabrication of a sapphire tool, characterizing its edge radius and using it for orthogonal cutting of OFHC copper, free cutting brass, and Al 6061. To fabricate sapphire cutting tools, a setup is developed where a series of processes like lapping, polishing and chemical mechanical polishing (CMP) are carried out to carve a sapphire tool with straight cutting edge, zero rake, and seven degrees clearance angle. The cutting-edge radius on Sapphire tool measured using the edge reversal technique was 432 nm. Orthogonal cutting of OFHC copper, free cutting brass, and Al 6061 was performed using the developed sapphire tool. The effect of cutting parameters, such as cutting speed and uncut chip thickness, on surface finish, cutting force, thrust force, friction coefficient, and chip morphology are investigated. It was observed that using the sapphire tool, smooth surfaces with average surface roughness ranging from 10 - 40 nm were produced on the machined workpiece surface. The cutting-edge of the sapphire tool after machining OFHC copper and free cutting brass remained intact with little wear. However, excessive tool wear was observed while machining Al 6061 due to built-up edge formation.