Method of forming a thermally conductive article using metal injection molding material with high and low aspect ratio filler

A method of forming a high thermally conductive article, comprising the steps of:

• providing a metallic base matrix of, by volume, between 30 and 60 percent;
• providing a first thermally conductive filler, by volume, between 25 and 60 percent;
• the first thermally conductive filler having an aspect ratio of at least 10:1;
• providing a second thermally conductive filler, by volume, between 10 and 25 percent;
• the second thermally conductive filler having an aspect ratio of less than 5:1;
• and
• mixing the first thermally conductive filler, the second thermally conductive filler and the metallic base matrix so that the first thermally conductive filler and the second thermally conductive filler are evenly dispersed throughout the metallic base matrix to form an entirely uniform molding composition;
• injection molding the uniform composition into a unitary monolithic thermally conductive article;
• the first thermally conductive filler and the second thermally conductive filler and the base matrix therein cooperating to reduce the number of thermal interface gaps in said monolithic thermally conductive article.