Abstract: The subject invention provides a method of manufacturing an all-metal cold plate heat exchanger assembly for removing excess heat from a heat generating electronic component. The cold plate assembly includes a base plate having micro-channels and associated micro-fins, a manifold plate having alternating channels, and a manifold cover, wherein the manifold plate cooperates with the micro-channels to form an engineered pathway for coolant flow. This method assures a tight interface sealing between the contact surfaces of the alternating channels of the manifold plate and the coplanar surfaces of the micro-fins that would prevent coolant by-pass flow, but without clogging or jeopardizing the flow through the micro-channels. This method utilizes a layer of recast metallic particulates, which is a natural by-product of laser machining, as a compliant gasket material between the coplanar edges of the alternating channels and the coplanar edges of the micro-fins.