Product Description
Our Rapid Sample Heatsink Service delivers precision-engineered thermal solutions tailored for high-power electronics and industrial systems. Utilizing 6063-T5 and 6061-T6 aluminum alloys with thermal conductivity up to 205 W/m·K, we extrude optimized profiles featuring variable fin densities (4-40 fins/inch), staggered pin arrays, and integrated heat pipe grooves. Prototype tooling is completed within 7 business days, supporting custom base thicknesses from 3mm to 25mm and overall dimensions up to 300mm width x 1000mm length. Secondary CNC operations include precision skiving for enhanced surface contact, threaded inserts for secure component mounting, and Type II/III anodizing for improved emissivity. Volume production benefits from our in-house extrusion presses with 800-ton capacity, ensuring consistency across 10,000+ unit orders.
Features
· Dual-Stage Extrusion: Combines direct and indirect extrusion methods for complex cross-sections.
· Thermal Simulation: CFD analysis optimizes fin geometry for specific airflow conditions.
· Surface Treatments: Hard anodizing (50μm) or nickel plating for harsh environments.
· Modular Designs: Interlocking segments for scalable cooling solutions.
· RoHS Compliance: Lead-free alloys meet EU environmental directives.
Applications
· Telecom: 5G base station amplifiers, fiber-optic transceiver cooling.
· Industrial Automation: VFD heat sinks, laser diode arrays.
· Transportation: Railway traction motor coolers, EV charging modules.
· Data Centers: Server rack cooling fins, GPU cluster thermal management.
FAQ
1. How are extrusion dies maintained for consistency?
Nitrided steel dies undergo ultrasonic cleaning and dimensional checks after every 50,000 cycles.
2. Can you create hollow heat sink channels for liquid cooling?
Yes, multi-port hollow profiles with O-ring sealing surfaces are available.
3. What’s the flatness tolerance on heat sink bases?
±0.05mm/m after precision milling and stress-relief annealing.
4. Do you provide thermal interface materials?
Optional thermal pads or phase-change materials can be pre-applied.
Aluminum Heat Sink
Extrusion: Aluminum alloy is heated and forced through a die to create complex geometries with optimized fin structures, maximizing surface area for heat dissipation. It offers high precision, excellent thermal conductivity, smooth surfaces, and design flexibility for custom shapes and sizes.
Die Casting: Molten aluminum is injected into molds under high pressure, ideal for producing intricate designs with thin walls and complex features. Suitable for high-volume production, though thermal performance may be slightly affected by porosity in the cast aluminum.
Stamping: Involves cutting and forming sheet metal using dies, ideal for simpler, lightweight heat sink designs. It is fast, cost-effective, and provides an economical solution for low-profile applications.
Advantages: Aluminum heat sinks are lightweight, strong, and possess good thermal conductivity. They are corrosion-resistant, recyclable, and provide design flexibility. These properties make them a popular choice in industries like electronics, automotive, and aerospace for reliable thermal management solutions.
