Cold Forged Heatsinks

Is the most effective method to form complex shapes and offers unique thermal advantages. Forging is a cold process. The part is formed under high pressure which controls the grain structure and results in improved thermal performance.

Forged fins can be made almost perfectly straight allowing for more fins per square inch. The fins can also be formed into an elliptical shape. The resulting increase in surface area can also be an important factor in improving thermal performance.

The forging process has few limitations to forming shapes and complex fin designs. A forged part is performed in two dimensions within the tool to create complex shapes without the need for secondary operations. Hole, chamfers, pins, elliptical fins., steps, etc. are created in the tool in a single operation.

Precisions forded heatsinks offer several important advantages over their machined, die cast and extruded counterparts. The increased thermal performance coupled with the ability to expand to surface area without increasing the size of the heatsink are unique advantages. These factors are especially critical when space is limited and /or weight reduction is critical to the product.

Precision forging can also produce complex shapes such as elliptical fins, staggered fins, round pin arrays, steps etc. within the tool. These features canned be achieved in an extruded or die cast part.

Finally, precision forged heatsinks can offer be manufactured at a lower cost because most operations can be performed in the tool and secondary operations are reduced.

Forging is also the most effective method for forming copper. Copper is difficult to extrude because it be heated to high temperatures to soften the metal. The can damage the extrusion tool. Secondary machining operations also result in expensive waste. Forging is a cold process, and copper heatsink can be formed with minimal waste.

Skived Fin Heatsinks

Skived Fin Heatsinks

The machining process for skived fin heatsinks uses cutting tools and a controlled slicing technique to manufacture heatsinks from a solid block of aluminum or copper. This process can be used to create heatsinks with thinner blades than are possible with extruded heatsinks. However due to the thin fins of this type of heatsink, greater care must be taken when handling them.

Benefits of Skived Fin Heat Sinks include:

  • High aspect ratio
  • Thin fin
  • Low tooling cost
  • Easy and inexpensive to prototype
  • Ideal thermal connectivity with the heat sink base
  • Unidirectional flow
  • Single piece construction
Folded Fin Heatsinks

Folded Fin Heatsinks

Folded fin heatsinks are manufactured by bending aluminum or copper sheets into a variety of fin shapes which are then bonded to a separate base. This type of folded fin heat sink allows the base and the folded fins to be manufactured from different metals.
This can be an excellent choice when your needs require a thin folded fin that can be light weight and with a different material for the base, thus lowering your overall materials and tooling costs.

If you are not sure that a folded fin heatsink is the right choice for your needs, our experts have knowledge that can help you make the right decision for both cost, tooling time and delivery date.

Simply call or e-mail us today to see what your options are. We feel confident that you will love our product costs and customer service, both during the sale and afterwards.

Bonded / Swaged Heatsinks

Our bonded / swaged heatsinks are manufactured from either aluminum or copper metal sheets, or by using an extrusion process. Using either an epoxy or a solder / braze process, the fin is bonded to the base, hence the name bonded fin.

The resultant bonded / swaged heatsinks are designed to meet very specific needs. Should you have any question about using bonded / swaged heatsinks, our knowledgeable consultants are available to discuss your specific needs and answer any questions you may have. It is important to choose the right product for cost, delivery time and effectiveness. The choice you make can crucial to your success.

Bonded / swaged heatsinks are generally designed for high power application accompanied with low thermal resistance. Forced air cooling is required for these bonded fin products.

A simple call or e-mail will put you in touch with the experts who have the answers you require.

Die Casting

Die Casting

Die cast heat sinks are perfect if you need a custom designed aluminum heat sink. They are manufactured by forcing liquid aluminum under high pressure into re-usable steel molds. This is often an ideal solution when you require a more complex design in high volume and with lower thermal conductivity.

Extruded Aluminum Heatsinks

Extruded Aluminum Heatsinks

Extruded Aluminum HeatsinkOur extruded aluminum heatsinks might be the perfect solution for your needs. Extruded aluminum heatsinks are the most popular type of heatsink due to their low cost and fast to market turn-around.

This type of heatsink is available in either standardized versions, or custom built to your specifications. During the manufacturing process, an aluminum block is either pushed or drawn (extruded) through a die to create either a straight or cross-cut finished heatsink. This extrusion process allows for complex fin designs to be created. As a result, we can provide a wide range of convection cooling characteristics suitable for high power components. 

Extruded aluminum heatsinks can be a great solution when you want to keep your tooling costs low and still achieve a low per piece cost, along with little or no secondary machining.

Custom Aluminum Extrusion Heatsinks

Extruded heatsinks can be made in a wide variety of shapes. Each process is designed to fulfill a different need. If you are not sure which is the right choice for your company, our experts can show you the benefits of each process to help you determine which aluminum heat sink extrusion will work best for your needs.

Advantages of Extruded Aluminum Heatsinks include:

  • Custom Extruded Aluminum HeatsinkHigh fin density can provide improved cooling performance
  • Lighter weight than copper
  • More efficient than stamped heat sinks
  • Low cost vs. machined assemblies
  • Wide variety of different designs can be customized
  • Flat backs useful for components such as power modules
  • Unique shapes geared for use in electronic power assemblies

These complex fin profiles allow greater heat dissipation through increased surface area while eliminating the cost and time associated with machining an equivalent shape from block aluminum. A simple call or e-mail will put you in touch with one of our experts.

Precision Machining

Cooling Source utilizes the latest multi-axis CNC center, milling, lathe, EDM and grinding machine to provide you complex and high precision heatsinks to a very high tolerance. The tolerance held depends on the machine but most precision CNC machines will not have a problem holding a tolerance of 0.002″ or 0.005 MM. We deliver affordable quality machined parts.

HeatPipe Assembly

Heatpipe Assembly

Our heat pipes are usually sintered or powdered copper, and can be manufactured under any type of orientation including horizontal, gravity aided or against gravity.

These heatpipes can handle high heat flux density, where the heat load is divided by the heated area. Our heat pipes assembly allows for great potential to increase your thermal performance with wick structures that can accommodate the increasing CPU thermal dissipation demands.

These heat pipes also allow for consistent thermal performance, which is optimal for high volume production. They can also be a perfect choice for more complex designs. If you are not sure which heatpipe is perfect for your needs, our knowledgeable experts can help you determine what your heat pipe requirements are, including a totally customized design

A simple call or e-mail will put you in touch with the answers you need.

Precision Forging

Precision Forging

Our Precision Forging process involves aluminum or copper that is pressed, pounded or squeezed under great pressure into high strength parts known as forging die. The process is normally (but not always) performed at a high temperature by preheating the metal before it is worked. This process can produce any fin type and high aspect ratio heatsink. Forged parts generally require further processing to produce the finished part.

Stamped Fin Heatsinks

Stamped Fin Heatsinks

Stamped fin heat sinks are manufactured by the application of extreme pressure to a piece of aluminum or copper to produce fins of the desired height, thickness and shape, which are then bonded to the heat sink metal base.
Stamped fin heat sinks are often recommended when you require a thin fin with limited thermal performance. They are characterized by a high tooling cost and low cost per piece.