Heat exchangers are crucial components in waste heat recovery systems to minimize heat loss from flue gas by efficient heat recovery. However, traditional plate-fin heat exchangers are limited by their fin shape due to manufacturing constraints. The emergence of additive manufacturing (AM) technologies has provided new opportunities for the design of heat exchangers with intricate fin shapes and improved geometric flexibility. One such innovative design is the usage of an airfoil fin, which can reduce form drag and subsequently lower the pressure drop. In this study, an additively manufactured airfoil plate-fin heat exchanger (APFHE) is analyzed numerically using OpenFOAM. Further, airfoil fin has been 3D printed to verify its printability without internal support structures. Subsequently, this research investigates the effects of various geometrical parameters of airfoil finned channel on pressure drop and heat transfer characteristics using air as the working fluid. The parameters studied include the offset number, longitudinal number, transverse number, and fin height of the airfoil finned channel. Thermal-hydraulic performance of airfoil fins is compared to conventional fins. The results indicate that airfoil fins outperform offset-strip fins with a fin thickness of 0.15 mm. In conclusion, the proposed airfoil fin heat exchanger is a promising solution for enhanced waste heat recovery with improved performance and eliminates complex joining processes such as vacuum brazing and diffusion bonding.