Process for fabricating heat sink with high-density fins

A process for fabricating a heat sink with high-density pin fins, comprising steps of:

• (a) providing a metal base comprising a first base and a second base, said first base being rectangular-solid shaped, said second base being rhombus-shaped and disposed over said first base wherein said second base comprises a first edge surface and a second edge surface inclined at a first specific angle and a third edge surface and a fourth edge surface inclined at a second specific angle;
• (b) cutting said second base from a first position on the top surface of said second base and parallel with said first edge surface until said first base is reached, thereby forming an inclined sheet;
• (c) adjusting said inclined sheet to be normal to the top surface of said first base, thereby forming a first fin;
• (d) repeating said step (b) and said step (c) to produce a plurality of said first fins;
• (e) cutting said second base from a second position on the top surface of said second base and parallel with said third edge surface until said first base is reached, thereby forming a plurality of inclined pins in a row;
• (f) adjusting said plurality of inclined pins to be normal to the top surface of said first base, thereby forming a plurality of pin fins in a row;
• and
• (g) repeating said step (e) and said step (f) step to produce a heat sink with high-density pin fins.