High performance circuits in electronic systems dissipate huge amount of heat. Efficient cooling is required to prevent such overheating. Simple and compact heat sinks can maximize convection for cooling machines and electronics. It is essential to adopt appropriate designs for cost minimization and cooling maximization. For metal removal, EDM uses a pulsating electrical charge of high-frequency current transferred from an electrode to the work-piece. It works well for finishing. This paper presents the optimal EDM parameters to realize the leaf-shape micro-channel AA 6061 heat sink by characterizing the surface finish. Current, pulse on time, and pulse off time are the EDM adjustments. Material removal rate (MRR) and surface roughness (SR) are the performance indicators. The three EDM parameters are organised in an orthogonal array according to Taguchi's method. The best EDM settings for achieving maximum MRR are shown to be distinct from the settings for achieving lowest surface roughness. The ideal EDM parameters for maximising MRR and minimising SR are determined using a straightforward and trustworthy multi-objective technique that takes into account the needs of the process designer. The MRR and SR are empirically derived as a function of the parameters of the EDM. The ranges of the estimated and tested values are quite similar