From Design to Finished Heat Sink
Custom aluminum heat sinks manufactured by extrusion,
cold forging, skiving or CNC machining—completed
with finishing and assembly when required.
Heat Sinks by Manufacturing Methods
Custom aluminum heat sinks manufactured using extrusion, skiving, cold forging, CNC machining, heat pipe integration, and die casting.
Straight-fin, linear, wide and constant-cross-section designs for efficient repeat production.
Integrated pin-fin or radial-fin structures for compact designs and multi-directional airflow.
Prototypes, low-volume parts and heat sinks with complex local machining features.
Thin, closely spaced fins where high fin density is required in limited space.
For transferring heat away from the source where a larger cooling area is needed.
Complex three-dimensional shapes and integrated thermal housings.
What We Need to Review Your Heat Sink
A complete drawing is preferred. A sketch, reference photo or basic dimensions can also be used for an initial review.
Please provide, where available:
- Overall dimensions and installation space
- Heat source location and mounting area
- Airflow direction or surrounding installation conditions
- Required holes, threads, slots, connector openings or assembly features
- Required length and finished-part dimensions
- Surface-finish and visible-surface requirements
- Sample and production quantity
We review the structure and recommend a suitable manufacturing route. Where extrusion or forging is considered, tooling feasibility is also checked before quotation.
Heat Sink Structures We Manufacture
Heat sink structures are developed according to installation space, airflow, mounting method and finished-component requirements.
Pin fin designs for efficient cooling in multi-directional airflow.
Straight fin designs for efficient cooling with directed airflow.
Plate fin designs for lightweight and cost-effective thermal management.
Round heat sinks for LED lighting and cylindrical electronic devices.
Custom heat sinks manufactured to your thermal and mechanical requirements.
Typical Heat Sink Applications
Custom aluminum heat sinks are manufactured for thermal management in industrial and electronic equipment.
Round, radial and pin-fin heat sinks for LED modules and lighting fixtures.
Heat sinks designed for power supplies and power conversion equipment.
Thermal components for controllers, automation and industrial electronics.
Cooling components for motor controllers, energy storage and related power equipment.
Design and Manufacturing Points We Review
The heat sink structure, manufacturing method and finished-part requirements are reviewed together before production.
Fin thickness, height and spacing are reviewed according to airflow, cooling requirements and manufacturing feasibility. Very thin, deep or closely spaced fins may require a different production method.
The base must provide sufficient area for heat sources and mounting hardware. CNC face milling can be used where controlled flatness or thermal contact is required.
Holes, threads, slots, connector openings and mounting features are reviewed together with the heat sink structure. These features are normally completed by CNC machining after forming.
Clear, black and hard anodizing, sandblasting, brushing, powder coating and painting can be selected according to operating conditions and appearance requirements. Visible surfaces and contact points are confirmed before production.
Prototype quantity, production volume and repeat-order requirements affect the suitable manufacturing method and tooling approach.
From Drawing to Finished Heat Sink
Each project is arranged according to the selected manufacturing method and finished-part requirements.
1. Drawing and Requirement Review
We review the heat sink structure, installation space, mounting features, and surface requirements.
2. Manufacturing Method and Tooling Evaluation
We select the suitable manufacturing route and review tooling requirements where applicable.
3. Prototype or First-Sample Confirmation
Samples are checked for structure, dimensions, machining features and surface requirements before volume production.
4. Main Production Process
The heat sink body is manufactured by the selected production route and prepared for secondary processing.
5. CNC Machining and Surface Finishing
Mounting surfaces, holes, threads, slots and other finished-part features are completed, followed by the required surface treatment.
6. Assembly
Hardware, inserts, end plates or other required components can be assembled according to the finished-part requirement.
Quality Control, Assembly and Delivery
Finished heat sink components are inspected according to the drawing, approved sample and final assembly requirements before shipment.
1. Dimensional and Machining Inspection
Overall dimensions, cut length, mounting surfaces, holes, threads, slots and other machined features are checked according to the finished-part drawing.
2. Fin and Structural Condition
Fin formation, spacing, damage, deformation and critical structural features are checked after the main production process.
3. Surface Appearance
Anodizing, coating, visible surfaces, contact points and batch appearance are checked according to the agreed finish requirement.
4. Assembly Fit
Where assembly is required, end plates, hardware, inserts and other components are checked for fit and function before packing.
5. Protective Packing
Heat sink components are separated and protected according to their size, surface finish and transport requirements.
Common Heat Sink Project Questions
How Do Thin Fin Thickness and Fin Spacing Affect an Aluminum Heat Sink?
Thin, deep or closely spaced fins increase surface area, but they also increase forming difficulty and reduce die strength. The fin geometry is reviewed together with profile width, base thickness and the selected manufacturing route.
How Is Flatness Controlled on a Wide Extruded Heat Sink Base?
Wide heat sink profiles can bow or distort during extrusion, cutting and secondary machining. Where a controlled thermal mounting surface is required, machining allowance, fixture support and CNC face milling are considered before production.
When Is Skiving Preferred Over Aluminum Heat Sink Extrusion?
Skiving can be considered for very thin, closely spaced straight fins that are difficult to form by extrusion. The final choice also depends on heat sink size, base structure, machining requirements and production quantity.
How Are Long Aluminum Heat Sinks Controlled During CNC Machining?
Long heat sinks require support points and fixtures that prevent vibration and movement without damaging the fins. Machining sequence is planned around the required holes, threads, mounting surfaces and any features on multiple faces.
Can a Heat Sink Include CNC-Machined Features on More Than One Face?
Yes. Holes, threads, connector openings, mounting surfaces and end features can be machined on different faces where the structure and fixture access allow it. The machining datum and clamping direction are reviewed with the finished-part drawing.
How Do Pin Fin and Straight Fin Heat Sinks Differ?
Pin fins allow airflow from multiple directions and are often used in compact or less-controlled airflow conditions. Straight fins are commonly used where airflow follows a defined direction through the fin channels.
When Is 6063 or 6061 Used for an Aluminum Heat Sink?
6063 is commonly selected for complex extruded profiles, visible surfaces and anodizing performance. 6061 may be considered where higher mechanical strength or specific machining requirements are more important.
How Does Heat Sink Base Thickness Affect the Final Design?
The base must provide sufficient rigidity, mounting depth and heat-transfer area for the installed component. It is reviewed together with fin structure, machining allowance and the required thermal interface.
Can Heat Pipes Be Integrated with Aluminum Heat Sink Components?
Yes. Heat pipes can transfer heat from the source to a separate aluminum cooling section where direct fin area is limited. The interface structure, installation space and assembly method are reviewed for each project.
How Are Visible Areas Managed for Anodized Heat Sink Components?
Visible surfaces, masking areas, hanging points and expected colour consistency are confirmed before finishing. This is especially important for black anodized parts, where small surface variations can be more noticeable.
Do You Have a Minimum Order Quantity for Custom Heat Sinks?
We do not set a fixed minimum order quantity. Projects from one piece can be reviewed, including samples and CNC-machined parts. For custom extrusion, cold forging or die casting, tooling and production setup requirements are confirmed according to the structure and quantity.
Need a Custom Heat Sink?
From engineering support to volume production, Glary provides custom aluminum heat sinks according to your drawings and specifications.
