<p>Miniaturising of cooling channel has emerged as a compelling thermal management solution, with an increase in significant interest in electronics, aerospace, and automotive applications. The efficient heat transfer enabled by mini cooling channels enhances the thermal performance and reliability of cooling systems. In addition, this advanced miniaturised cooling technology offers compelling advantages such as compactness, lightweight design, and the flexibility to fulfil specific cooling requirements. However, due to the compact and customised configuration of mini channels, it is crucial to analyse the flow uniformity while optimising the thermal efficiency. This paper is focused on the parametric design study of a mini cooling channel encompassing aspects such as channel geometry and flow configuration. Specifically, it discusses the impact of design parameters on fluid flow dynamics inside a cooling channel. The initial phase employed computational fluid dynamics simulations to identify an optimal mini-channel configuration. This optimal model was then fabricated using additive manufacturing techniques. Subsequently, the experimental validation stage involved pressure drop and flow visualisation in the physical model to corroborate the CFD findings.</p>