I have seen all three methods (dollop or line and press, spread with baggie over your finger, spread thin with a flat edge like a credit card or razor blade) described by various groups with varying results. I think in the end, what you want is the thinnest layer of TIM that fills all gaps between the CPU and the HS. If you think about it though, there are a lot of variables and possible pitfalls to consider.
The dollop (or line depending on your proc) and press is the safest way to ensure you don't trap bubbles. Air is going to be far worse than just a thick layer of TIM, so I think that is why this is the preferred method from vendors. The problem is that it is difficult to get a very thin layer of TIM while pressing, especially with the thicker TIMs.
I think the spread-it-yourself method could work very well (speaking from logic and not personal experience) if it is done properly. But I think it may be harder to do properly than most people realize. Let's think about some crucial points/pitfalls.
Spread it thin - I read the
article posted above a few weeks ago and the picture with the
TX2 just amazed me. If you're going to spread the TIM that thick, you might as well use the dollop method and avoid the risk of trapping bubbles. I think the whole advantage of spreading your own is that you start off with a layer thinner than you could press down to, otherwise its pointless. You can easily get full coverage with the dollop method.
Spread it flat - OK, you've just spread that goop with your bagged finger and now it has little hills and valleys all over it. Once you put you flat HS down on it, where do you think the air in those valleys is going to go? Seems like a flat edge is really important for smoothing the TIM as flat as possible before assembly.
Flat HS base? - I've heard a lot of people testing their HS and finding the bas eis concave before lapping. Even if you have a perfectly flat layer of TIM on your CPU, it seems like a concave HS base is going to cause problems trapping air. If you know you have a concave surface, I think you have to either lap it or go with the dollop method.
Not too shiny - I can't find it now, but I recently read an article where I guy actually varied the level of polish on a HS (for a laser in his lab, but the same kind as for procs) to see the effect on thermal transport using the same TIM as computers use. To their surprise, they found an optimal roughness (using about 800-1000 grit sand paper). Putting a mirror finish actually degraded performance a little. The hypothesis is that the micro grooves created by the 800 grit sandpaper were able to push through the thin TIM layer and make direct metal-metal contact.
After all these pitfalls/requirements I've thought up, and reading a lot of reviews on the matter, I have trouble finding a comprehensive test that takes them all into consideration. I don't really trust a lot of the results out there comparing methods because they rarely take all these things into account. All that being said, you might notice that it is much simpler to go with the dollop method. Its no wonder that most manufacturers recommend it.
Tim