3 methods you should know to customize the aluminum heatsink

Aluminum heatsinks are getting more and more popular among manufacturers. Although it may not have the best thermal conductivity, aluminum is still the most popular material for heatsinks due to its relatively low cost and ease of fabrication. Additionally, aluminum’s high-strength-to-weight ratio offers the possibility for lighter weight heatsinks that can be more easily mounted on boards.

This article will cover three methods you can use to customize your aluminum heatsink to fit your needs.

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Aluminum extrusion: the ideal process to customize the aluminum heatsink

Aluminum extrusion is a manufacturing process in which a solid aluminum ingot is transformed into a finished product by forcing the aluminum through a die. In engineering, aluminum extrusion has become one of the primary methods to custom the heatsinks.

The aluminum extrusion process is quick, giving less turnaround time between iterations and a more accurate final product with high accuracy. The cost of an extrusion process is also much lower than other production methods, making the process very affordable for the market. Without question, aluminum extrusion should be a top consideration for manufacturing the custom heatsink

Extruded aluminum heatsinks could be precisely machined to fit the assembly of their end-products and use different profiles for different purposes. It is a cost-effective way to create an efficient heat dissipation system as this process reduces time, costs, and errors.

But unfortunately, aluminum extrusion is also limited, especially regarding the width and thickness of the fin to a custom extruded aluminum heatsink.

Firstly, The width of the aluminum extrusion is limited by the extrusion press used to make it. It would be too heavy and difficult to fit the extrusion press. A custom design of aluminum heatsink needs to be evaluated, and to choose the most cost-effective way to produce it.

On the other hand, the thickness is a critical parameter in determining the heatsink’s performance. Reducing the fin thickness below the minimum permitted is typically not permissible. Otherwise, the extrusion for the aluminum heatsink will get deformed.

If you have an aluminum extrusion design ready for heatsink manufacturing, contact us to get a free evaluation on cost and feasibility.

aluminum extrusion heatsink

Aluminum casting: To Creat complex shapes of aluminum heatsink

Die casting is a process used to create intricate shapes where the material being released is malleable, such as cast aluminum. This process has been around for about a century and has constantly progressed. The die casting technology allows us to produce complex shapes with high precision and repeatability. In this way, we can make heatsink with complex geometry that would be impossible by other methods.

Die casting technology is a highly efficient and sustainable way of producing heatsink, which can be made more easily in different shapes and sizes since molds can be designed for any type or form that the customers require. The large-scale production of aluminum dies casting has helped the industry develop complex shapes with high precision and repeatability.

With the development of society, thermal management has become an urgent problem. The die-casting aluminum with low density is an ideal material for the heatsink because it is characterized by strong thermal conductivity and fast dissipation. 

The heatsink is a necessary part of cooling system of any electronic device, in order to provide a good thermal conductivity. It is well-suited for use in automobiles, laptops, lighting, and other high heat generating equipment.

Aluminum skiving: the process of cutting material off in slices

Aluminum Skiving is one of the most commonly used manufacturing processes for fabricating aluminum heatsinks. Today, more and more fabrication companies are using this process to ensure that they can meet the requirements of their customers.

Skiving involves cutting the piece away from the block, taking off a thin slice at a time with a particular tool called a skive cutter. This process aims to create long surfaces on the material to which heat can be applied evenly. The two main categories of heatsinks are plane heatsinks – where there are no holes in the center – and vented heatsinks – where there are many holes in each side of the material.

Aluminum heatsinks are the most common part of cooling devices.
While most aluminum heat sinks are made from extruded aluminum, the size limits for an aluminum extrusion have traditionally been based on the maximum dimension for a given extrusion die opening.

The skiving aluminum heatsink is a type that is developed to improve thermal conductivity. Thinner than the extruded allows greater flexibility and improved thermal conductivity, which enables significantly increased use of aluminum as a heat sink with high-power machinery and equipment.

Professional Guidance in aluminum processing

It’s difficult or impossible to select the processing with your limited knowledge, especially if you’re a novice. You’re also worried about what the final product will be. We provide professional Guidance on design feasibility and modification, with rich experiences in various solutions to fulfill your expectation.

Our professional Guidance aims right at your goals and dreams. With our Guidance, you can avoid pitfalls, short-cuts that lead to waste, and disappointments as we provide you with the best solution for a satisfying result.

Contact us for professional Guidance, It is time to stop wasting time and money now!