Injection Molding
Tooling and molding for your repeat plastic parts.
YOUR DRAWING · YOUR OPERATING CONDITIONS
Custom Heat Sinks
for Your Mounting, Airflow & Production Needs
Bring your drawing, heat load and available space into one review. Plan your aluminum or copper heat sink around mounting interfaces, manufacturing route, surface finish and agreed acceptance requirements.
Illustrative component concept
Heat load
Power, ambient & airflow
Interfaces
Contact face & mounting
Manufacturing
Material, route & quantity
Acceptance
Sample, checks & records
Start with Your Assembly Requirements
Your heat sink has to fit the device and the build plan. Review mounting, contact, airflow and repeat demand before selecting how to manufacture it.
- Fit the available mounting envelope
- Identify your real heat-source footprint
- Use installed airflow and orientation
- Review material and one-time tooling costs
- Agree the sample and inspection evidence
Mounting features
Allow tool and fastening access around your hole pattern.
Contact faces
Define the device footprint, TIM and clamping stack.
Fins and airflow
Review channel clearance in the installed assembly.
Samples and repeat supply
Agree handling, sample checks and the released revision.
Compare 4 Manufacturing Routes for Your Geometry
Choose the route around your material, interfaces and order quantity. Drawing review confirms availability and manufacturing scope for your part.
CNC-Machined Heat Sinks
Review interrupted geometry, tool access, fin rigidity and material removal.
Review this route →
Skived Fin Heat Sinks
Review integral thin fins, material condition and installed airflow.
Review this route →
Extruded Heat Sinks
Compare an available section with a new die; specify cutting and machining.
Review this route →
Bonded Fin Heat Sinks
Review separate fins, base grooves, joint construction and agreed checks.
Review this route →Choose the Route Around Your Part
DRAWING & INTERFACES↓MATERIAL & ROUTE↓SAMPLE & AGREED CHECKS↓APPROVED FINISHED PART
A new extrusion die is only one option. For your custom heat sinks, compare machining from stock, modifying an existing profile and a dedicated forming route before you commit to tooling.
- Define the heat-source footprint and available volume.
- Review critical geometry before material and tooling commitment.
- Approve a route-specific sample and controlled drawing.
Compare Material Data Before Your Cooling Decision
Use bulk material properties to compare conduction and mass. Your finished part still needs geometry, mounting and airflow review; these figures are not LK MFG heat sink test results.
Typical thermal conductivity
6061-T6: Hydro, 25°C. 6063-T5: Gabrian typical value. Cu-ETP: KME, annealed at 20°C.
Density: check your mounting load
For the same metal volume, Cu-ETP is approximately 3.30× the mass of aluminum. Geometry changes the finished-part mass.
| Grade | European designation | Si | Mg | Cu | Fe | Mn | Cr | Zn | Ti | Al |
|---|---|---|---|---|---|---|---|---|---|---|
| 6061 | EN AW-6061 · AlMg1SiCu | 0.40–0.80 | 0.80–1.20 | 0.15–0.40 | ≤0.70 | ≤0.15 | 0.04–0.35 | ≤0.25 | ≤0.15 | Balance |
| 6063 | EN AW-6063 · AlMg0.7Si | 0.20–0.60 | 0.45–0.90 | ≤0.10 | ≤0.35 | ≤0.10 | ≤0.10 | ≤0.10 | ≤0.10 | Balance |
| C11000 | Cu-ETP · CW004A | — | — | ≥99.90 | — | — | — | — | — | — |
Copper designation: UNS C11000 ↔ Cu-ETP / CW004A; KME composition: Cu ≥99.90%, O ≤0.040%. Confirm standard, product form and material condition. The designation is a grade-family reference, not blanket interchangeability with every “C1100” or “1100” label.
The dash (—) means not specified in this selected-element summary, not zero. For aluminum: other elements ≤0.05% each / ≤0.15% total. Values are reference limits; the ordered standard and material certificate govern. Confirm grade and temper feasibility for custom heat sinks.
Material sources: Hydro 6061 · Gabrian 6063 · KME Cu-ETP
Read Your Thermal Evidence Under the Same Conditions
Three views for your review: a calculation, a resistance budget and a heat-path diagram. All examples below are illustrative—not measured part performance or a CFD result.
1 · Power and temperature rise
Example only: ΔT = Q × R. At a hypothetical R = 1 K/W, 50 W gives a 50 K rise. R must come from your defined path and actual operating conditions.
2 · Set the resistance budget
Illustrative allowable total R = (75°C − 25°C) / Q. This is a 50 K budget from the chosen reference point to ambient; include interfaces on that path.
3 · Follow the heat path
YOUR HEAT SOURCE↓TIM & CONTACT FACE↓BASE → FINS → AIR
Review contact, spreading and convection together. For a measured curve or CFD report, agree the geometry, heat source, airflow, orientation and validation scope first.
For your acceptance report: define power, heat-source area, TIM and mounting, sensor positions, ambient, installed airflow or velocity, orientation and stabilization. Do not compare CFM, LFM and fan free-air ratings as interchangeable conditions.
Review Your Surface Finish
Specify the visible surfaces and functional contacts separately. No coating gives a universal cooling improvement. Identify the contact pads and critical bores on your controlled drawing.
Confirm alloy, surface preparation, film and masking.
Specify appearance and keep thermal or electrical contacts controlled.
Review substrate preparation, coating thickness and required contact surfaces.
As-machined surfaces and selective coatings are reviewed against your drawing. Powder coating needs specific review of fin gaps, thickness and masked contact areas. Anodizing applies to aluminum, not copper.
Define Your Functional Features
Put the dimensions that control fit and heat transfer on your drawing.
Mounting holes
Hole pattern, datums and assembly loads
Threaded holes
Thread standard, depth and tool access
Slots & cutouts
Cable clearance, fixtures and interruptions
Contact surfaces
Footprint, flatness and surface condition
Base & fins
Base thickness, fin envelope and usable air path
Resolve 6 Fit & Airflow Questions Before Production
Define your operating conditions and mating features before selecting a manufacturing route.
Define Your Device Contact
For your heat sink machining services, identify the device footprint, base datums, mounting holes and assembly keep-outs. Specify heat sink base flatness with the inspection method and clamping condition, rather than applying a tolerance to every surface.
Your contact area, TIM and clamping condition determine which face needs a flatness requirement. Specify the datum and measurement state.
01
Device footprint and keep-outs
02
TIM and insulation stack
03
Datums and final inspection
04
Clamping and assembly condition
Illustrative component review concept
Match Your Fins to the Air You Have
Do not select fin density from appearance alone. Review installed flow, fan pressure, bypass and orientation.
01
Fin thickness and clear spacing
02
Flow direction and fan curve
03
Duct and bypass clearance
04
Thermal test operating point
Illustrative component review concept
Keep Your Part Accessible for Assembly
Review mounting holes with fasteners, tools, cable routes and the contact plane. Include the mating specification.
01
Hole pattern and threads
02
Fastener and wrench access
03
Module and cable keep-outs
04
Assembly datum scheme
Illustrative component review concept
Select Your Full Grade and Condition
Compare conduction, mass and manufacturing feasibility. A material property does not alone establish device temperature.
01
Grade and product standard
02
Temper or copper condition
03
Mounting load and mass
04
Sample material evidence
Illustrative component review concept
Control the Surface That Meets Your Device
Review finish and masking with your thermal, electrical and dimensional interfaces. Apply coating requirements only to suitable substrates.
01
Coating and thickness
02
Thermal and electrical pads
03
Threads and precision fits
04
Burrs and final cleanliness
Illustrative component review concept
Agree Your Evidence Before Release
Separate material identity, dimensional inspection and system thermal validation. State what your quotation and sample approval include.
01
Controlled drawing revision
02
Critical dimensions and fit
03
Defined thermal conditions
04
Sampling and required records
Illustrative component review concept
5 Checkpoints from Drawing to Repeat Supply
Drawing
Confirm revision and critical interfaces.
Route review
Agree material, geometry and manufacturing scope.
Sample
Check your finished part and assembly fit.
Evidence
Review agreed dimensions and separate thermal test scope.
Repeat supply
Release the approved revision and packaging.
Separate Fit Approval from Cooling Approval
Illustrative component concept
Heat sink prototyping should confirm the controlled drawing, mounting stack and agreed inspection records. Low volume heat sink manufacturing still needs a defined material, finish and repeat-order revision. Dimensional inspection does not prove thermal performance.
- Material identity and controlled drawing revision
- Contact faces, mounting dimensions and fit
- Finish, burrs, fin condition and protection
- Agreed records, sampling and shipment release
Applications to Review for Your Part
Project suitability, manufacturing scope and required records are confirmed from your drawing. These are application review topics, not customer case studies or system certifications.
Industrial automation
Review control cabinets, motor-drive enclosures and service access.
Power electronics
Match the module footprint, mounting load and insulation.
EV & charging
Review device heat load, mounting and environmental conditions.
Telecom equipment
Review airflow direction and the available enclosure volume.
LED lighting
Specify the board interface, orientation and ambient conditions.
Server components
Review the exact device and installed airflow; no generic fit assumption.
Test equipment
Plan instrument clearances, fixture mounting and service access.
Energy systems
Review power modules, ambient range and the assembly envelope.
6 Inputs for Your Custom Heat Sink Quote
- CAD + controlled drawing
- Heat load + temperature target
- Airflow + installation orientation
- Contact face + mounting interfaces
- Material, temper + finish
- Sample quantity + repeat demand
Your quote should identify tooling, component manufacture, finishing, inspection and any separately agreed thermal validation. Manufacturing in China with Dallas-area coordination.
Answers Before You Specify
What information is needed for a custom heat sink manufacturing quote?
Send CAD and a controlled drawing, sample and repeat quantities, heat load, ambient temperature, airflow or natural-convection conditions, mounting interfaces, material, finish and acceptance requirements.
Can an existing heat sink extrusion be modified instead of making a new die?
Compare its actual cross-section with your available space and mounting needs. Cutting, drilling and milling an existing section may avoid a new die; stock availability and machining scope must be confirmed.
Can you manufacture ten custom copper heat sinks?
Submit the geometry and quantity for review. Thin tall fins, stock size, material removal and inspection affect feasibility and price. The quote confirms the minimum order and manufacturing route for your part.
Does switching from aluminum to copper guarantee a lower temperature?
No. Copper can improve conduction, but airflow, fin geometry, contact resistance, mounting and the heat-source footprint also control temperature. Compare the complete assembly under the same conditions.
What should a heat sink quotation separate?
Ask for tooling and other one-time costs, part manufacturing, surface treatment, assembly, inspection and any agreed thermal validation to be identified separately.
Which surfaces should be masked before anodizing?
Identify thermal contact pads, electrical contacts, threads and precision fits on your drawing. Confirm the coating and masking requirements with the mating assembly.
