The 2D arrangement of highly-anisotropic graphite flake (Gf) in the Al matrix composite was achieved by combining the step-by-step powder filling method and flake powder metallurgy using the specifically-designed punch. Compared with the conventional 1D arrangement, its advantages are to improve thermal conductivity as well as to reduce coefficient of thermal expansion being compatible with that of the substrate material. This technical advance can open up a door towards thermal management applications of the low-cost Gf/Al composites.