I am designing a thermo-electric generation system that would generate electricity from the heat of my wood stove. The active components are bismuth telluride TEG cells that use the Seebeck effect in reverse to convert a temperature difference into an electrical voltage.
The surface of the flat cell facing away from the wood stove needs to be cooled by a heat sink and fan so the semiconductor is not damaged.
I would like to fashion an aluminum heat sink out of waste aluminum (foils, baking sheets, trays, etc).
Update: What I had in mind was a metal brake and bending system to fashion the fins and then bonding the fins to a flat piece of aluminum with a layer of heat sink compound adhesive. Since the waste aluminum is thin and easily malleable, this should be trivial. Melting it down and pouring into a mold in a vacuum would not be worth it.