Custom Aluminum Heat Sink for Electronics

Product Overview

This precision-engineered solution utilizes 6063-T5 aluminum alloy with a thermal conductivity of 201 W/(m·K), enabling efficient heat dissipation that maintains optimal operating temperatures for sensitive electronics. Unlike generic heat sinks with one-size-fits-all designs, our custom solutions feature tailored fin geometries, base thicknesses, and surface treatments that match specific thermal resistance requirements, reducing component temperatures by up to 45°C compared to standard cooling solutions. The combination of advanced aluminum extrusion and CNC machining ensures precise thermal contact, making these heat sinks ideal for applications ranging from consumer electronics to industrial power systems.

Product Features

High-Efficiency Thermal Design: Optimized fin density (10-40 fins per inch) and 0.3mm fin thickness tolerance maximize surface area while minimizing airflow resistance, achieving thermal resistance as low as 0.2°C/W for rapid heat transfer.

Premium Aluminum Alloy: 6063-T5 aluminum provides an ideal balance of thermal conductivity (201 W/(m·K)) and mechanical strength (110 MPa tensile strength), with excellent machinability for complex geometries.

Custom Surface Treatments: Optional anodizing (20-50μm thickness) enhances corrosion resistance (1000-hour salt spray resistance per ASTM B117) and improves thermal radiation, while thermal interface materials (TIM) pre-application ensures immediate installation readiness.

Precision Manufacturing: CNC-machined base plates with ±0.05mm flatness tolerance ensure intimate contact with heat sources, reducing contact resistance by 60% compared to stamped metal alternatives.

Product Applications

LED Lighting Systems: High-power LED fixtures benefit from the 45°C temperature reduction, extending diode lifespan to 50,000+ hours in architectural and industrial lighting applications.

Power Electronics: Inverters, motor drives, and battery management systems utilize the custom designs to handle power densities up to 200 W/cm² in renewable energy installations.

Consumer Electronics: Slim-profile heat sinks enable passive cooling in laptops and gaming consoles, reducing noise by eliminating fans while maintaining performance during extended use.

Automotive Electronics: Underhood and infotainment systems withstand -40°C to 125°C temperature extremes with vibration resistance (20G shock rating per IEC 60068-2-27).

FAQ

Q: What customization options are available for specific thermal requirements?

A: We offer full customization of fin height (5mm-150mm), base dimensions (20mm×20mm to 300mm×300mm), and surface treatments. Thermal simulation services ensure designs meet target ΔT with ±2°C accuracy.

Q: How does anodizing affect thermal performance?

A: Our clear anodizing process adds only 0.02°C/W thermal resistance while providing corrosion protection, making it ideal for humid environments like outdoor electronics enclosures. Black anodizing enhances radiation cooling by 15% in natural convection applications.

Q: What is the minimum order quantity for custom designs?

A: We support low-volume production starting at 50 units with rapid prototyping (7-day turnaround) using CNC machining, scaling to 10,000+ units/month via extrusion for high-volume applications.

Q: Can heat sinks be designed for liquid cooling integration?

A: Yes, custom designs can incorporate water channels with 0.1mm surface roughness for liquid cooling systems, achieving thermal resistance as low as 0.05°C/W for server and data center applications.