Stamped Board Level Heat Sink
For board-level heat sinks with simple structures, we can use stamping or extrusion processes. Stamped heatsinks are made from sheet metal that has undergone a progressive stamping process, adding details and features as each metal stamps through the die.
Stamped heat sink geometries are designed for specific electronic package types to ensure optimal mounting and functionality on the PCB. These heatsinks can be passive or active, based on adding a fan, and are often used to increase airflow across a board or system.
Extruded Aluminum Heat Sink
Extruded aluminium is one of the most popular and cost-effective to manufacture. The size range of extruded heat sinks depends on the application, being smaller for board level and larger for medium power applications. They can be designed for passive or active cooling depending on the fin shape and pitch. Board-level extruded heatsinks are commonly used in packages such as BGAs and FPGAs.
Choosing the right extruded heat sink is largely dependent on the desired profile. Extruded heat sinks are made by creating profile dies that determine fin density, spacing and length, as well as base height and width. The softened aluminum is pushed through the die to form a long rod, called a bristle, with the same profile and dimensions as the die. Then cut the bars into smaller standard shape bars/rectangles or custom lengths. These are further machined and finished to create custom heat sinks. The process is fast, cost-effective and scalable; this is why many people consider extruded heat sinks in the first place when looking for a solution.
Cutting Heat Sink
Scraping is a fabric made from a single piece of metal with layers sliced from the top part of the base. The layers are folded back perpendicular to the base, and the process is repeated at regular intervals to create the fins. The one-piece construction reduces thermal resistance because there are no joints or materials between the fins and the base. The process also enables high fin densities and thin fin geometries, resulting in a larger heat sink surface area and higher heat transfer.
Unlike extruded heat sinks, cut fin heat sinks do not rely on tooling and multiple steps; instead, they use one cutting tool, which reduces tooling costs, increases design flexibility, and speeds prototyping.
Die-cast Heat Sink
Die-cast heat sinks are one-piece construction. They are mainly produced in high volume for applications that are weight sensitive, require excellent cosmetic surface quality or have highly complex geometries. These solutions work by pouring thermally conductive alloys into near-net-shape custom molds, which are then lightly machined and finished in the final product.
The above radiators are all manufactured by precision CNC machining. I have very high precision on the products and at the same time ensure the quality of the radiators.