<p>Structured fins with complex geometries are extensively applied in high-end fields such as aerospace and electronic heat sinks, wherein stringent requirements for forming accuracy, array uniformity, and thermal contact performance severely restrict their efficient manufacturing. While conventional methods—such as milling, rolling, and electrical discharge machining—can fabricate such microstructures, they remain constrained by high energy consumption, low efficiency, and poor morphological consistency. To overcome these limitations, this study proposes a novel electroplastic-assisted ploughing extrusion-cutting (EAPE-C) method for fabricating structured fins. Integrating the efficiency and flexibility of ploughing extrusion-cutting, the electroplastic effect is introduced into an electro-thermal-mechanical coupled processing regime. Under the synergistic action of Joule heating and electron wind force induced by pulsed current, the yield strength of the workpiece decreases, thereby promoting the plastic flow of pure copper. Experimental results indicate that elevating pulse peak current and frequency intensifies this coupling effect, significantly enhancing plastic extension along the height direction. This manifests as a progressive increase in fin height, accompanied by slight reductions in width and bottom thickness. Compared to conventional PE-C, EAPE-C effectively improves material flowability, mitigates surface tearing, and transforms surface morphology from rough to smooth, substantially improving geometric consistency. Further analysis reveals that increased spindle speeds facilitate fin height growth and width reduction, whereas larger feed rates suppress height development and increase width. Metallographic observations and shear slip-line analysis corroborate the role of the electroplastic effect in promoting plastic deformation on plastic deformation, establishing the mechanical foundation for stable fin formation.</p>