Abstract: A three-dimensional geometry of a thermal interface body may be customized to substantially fill an irregular gap along a thermal dissipation pathway in an electronic package. The thermal interface body is fabricated through an additive deposition process, wherein sequential patterns of thermal interface material are coherently connected to other deposited patterns of thermal interface material.

Abstract: A system having a removable electronic component employs an abrasion-resistant thermally conductive film as a thermal interface between the removable electronic component and a heat sink. The abrasion-resistant film reduces thermal impedance between the removable electronic component and the heat sink when the removable electronic component is repeatedly installed and removed from a chamber in a host device. The abrasion-resistant film includes a polymer formed from a silicone-containing resin and an inorganic particulate filler; the film may also be interlocked with a corrosion protection layer at the heat sink. A method of forming a heat sink is provided that minimizes increases in thermal impedance.