Green and sustainable practices in machining that offer cost-effectiveness, reusability, reduction in energy, resources, and overflow are always encouraged to fulfil the vision of an environmentally friendly manufacturing sector. The present research marks its significance in this context, discussing the design and development of a custom-configurable and re-usable grinding wheel for surface grinding with the aid of additive manufacturing. A modular grinding wheel, geometrically analogous to insert type tool and/or tyre-wheel unit of automobiles, with a re-usable base wheel and custom-configurable abrasive segments attached on it, generated via Fused Deposition Modelling (FDM) and Laser Powder Bed Fusion (LPBF), has been presented. Experiments using the proposed wheel, in comparison with traditional electroplated CBN wheel, showed superior grinding performance and surface topography. Application of the proposed wheel in segmented mode could effectively breakdown the boundary layer around the rotating wheel and shown a 31.58% reduction in grinding force, a 6.83% reduction in average roughness, and a 34.68% reduction in grinding temperature at selected cutting conditions. In addition to the re-usability of base wheel and reconfigurability of abrasive segments, the possibilities of internal passages in base wheel for coolant delivery have also been demonstrated, which showed a 56.31% reduction in grinding temperature as compared to flood cooling.