The effectiveness of improvising heat transfer material when building heat sinks gave rise to the concept for this study. The development of composites, more specifically, aluminum matrix composites (AMCs), which are the parent material of heat sinks, led to the evolution of this idea (AA 6061). The viable low-cost stir casting process for composites manufacturing has two significant drawbacks: agglomeration and non-uniform dispersion. This study investigated the efficient dispersal of reinforcement fragments in base metal (AA 6061 T-6) using the patented two-step stir casting method and the innovatively fed exemplary encapsulation method. This study’s optical and scanning electron microscopy photos verify the reinforcement’s equated dispersion. Thermo-Mechanical Analyzer (TMA), Dilatometry Tester, Laser Flash Apparatus (LFA), and pin–fin apparatus verify the newly designed potential substitute material for fabrication of the heat sinks. © 2024 Elsevier B.V., All rights reserved.