This paper presents a numerical simulation and optimisation of a complex microchannel featuring innovative fin designs. The primary objective of the study is to minimise resistance in the heat sink by utilizing intricate fin structures. Three different approaches are explored: firstly, cylindrical solid fins are designed and placed on the heat sink; secondly, the solid fins are drilled halfway (50 %); and in the third scenario, the solid fins are drilled 87.5 % and mounted on the heat sink. In the simulation set-up, the heat sink has a heat load of 250 W imposed on the bottom wall and single-phase water of Reynolds number between 400 and 500 flows in a forced convection laminar condition to remove the heat at the bottom and internally within the fins walls surface area, while an air stream of Reynolds number between 3 and 6 flows convectively across the cylindrical fins to dissipate excess heat externally. The finite volume method and computational fluid dynamic code, are employed to discretise the geometry with heat and fluid fields solved. The optimisation is performed for parallel and counter flows and the outcomes compete favorably. Similarly, the influence of the Reynolds number on minimised temperature and resistance results is discussed. The results show that in parallel flow the integrated heat sink with half hollow fins is best with a minimised resistance of 27.2 %, while in the counter flow the hollow fins are superior with a declined resistance of 19 %. The study is validated with experimental results in open literature.

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