Aiming at studying the influence and importance of the geometrical parameters on steel HPD type offset strip fin performance, this paper reports experimental and numerical studies at low Reynolds number. A novel test rig with electrically heated single layer fin assembly as test object was constructed. Only the effects of fin height and fin wavelength on the fin characteristics were considered because of the pressing mould limitation. Through comparisons of experimental, simulated and Muzychka's results, the tendencies agree well. The deviations between them are due to the difference of fin material and the influences of the pressing mould process technique on the fins. Based on the Taguchi method and uniform design, the importance of the geometrical factors on the fin thermal hydraulic performance was investigated. The sequence of degrees of effect for each parameter is s, h, alpha, s(0), b and t. The paper obtained the optimum model and numerically proved its validity among the considered ranges. Eleven sample fins were collected during different periods of the mould life time, and the influences of mould wear on fin friction performance were examined. The mould wear includes three stages, and the performance of fins pressed during 100 thousand times to 1,050 thousand times is more stable. The recommended life time for the mould type is about 1,050 thousand times. (c) 2007 Elsevier Ltd. All rights reserved.