In this work, we designed a novel cross-process matching method and technology through sensing signals and dimensional fitting. Specifically, we mixed the electrochemical machining and sinking electrical discharge machining methods with intelligently designed special-shaped electrodes to effectively enable virtual measurement and dimension maintenance by developing intelligent electrode-processing technology for nickel-based superalloy special-shaped electrodes. The technique can help directly adjust the product accuracy of special-shaped holes on the basis of the relationship between the amount of material removed and the current by revealing errors across processing, obtaining feedback, and maintaining accuracy through matching methods without offline measurement. With a lot of time and design adjustment parameters, this method can provide more accurate and faster results than the traditional method. The electrode wear after 17 h of continuous processing is ≤10%. Processing accuracy control during discharge is ≤±0.5 µm. The processing time of the rough/medium machining process is ≤24 h, which is an increase of ≥40%. Moreover, the electrical machining process optimization improved aerospace diffuser processing efficiency by 30%.