Professional Cold Forged Heat Sink Manufacturing Services
Advanced precision cold forging technology delivering superior thermal performance for LED lighting, automotive electronics, and high-power cooling applications. Experience up to 14% better thermal conductivity compared to extruded alternatives.
What is Cold Forged Heat Sink Technology?
Cold forging is an advanced manufacturing process that shapes aluminum and copper heat sinks using localized compression forces at room temperature, creating superior thermal management solutions with unmatched precision and performance.
Revolutionary Manufacturing Process
High-Pressure Forming
Utilizes extreme compression forces to shape metal billets into complex geometries without heating, preserving material properties.
Room Temperature Process
Cold forging at ambient temperature eliminates thermal stress and grain structure changes, resulting in superior mechanical properties.
Precision Engineering
Achieves tight tolerances and complex pin fin configurations with aspect ratios up to 50:1, impossible with traditional methods.
Advanced Cold Forging Manufacturing Process
Our state-of-the-art cold forging equipment and precision engineering deliver heat sinks with exceptional thermal performance and dimensional accuracy.
Material Preparation
High-grade aluminum 1070/6061 or copper billets are precisely cut and prepared for the forging process.
High-Pressure Forming
Specialized hydraulic presses apply up to 400 tons of force to shape complex fin geometries with precision.
Precision Machining
CNC machining ensures exact dimensions and surface finishes meeting the tightest tolerances.
Quality Control
Comprehensive testing and inspection ensure every heat sink meets performance specifications.
Cold Forged Heat Sink Product Range
From precision pin fin designs to custom LED cooling solutions, our cold forged heat sinks deliver exceptional thermal management across diverse applications.
Pin Fin Heat Sinks
High-density pin fin arrays with exceptional aspect ratios up to 50:1, optimized for forced convection cooling applications.
- Aluminum 1070/6061 & Copper Options
- Pin Density: 0.5-2.0 pins/cm²
- Thermal Resistance: 0.15-0.8°C/W
LED Heat Sinks
Specialized designs for high-power LED lighting with integrated mounting features and optimized thermal pathways.
- Power Range: 10W-200W LEDs
- Junction Temperature: <85°C
- Custom Mounting Options
Copper Heat Sinks
Premium copper cold forged heat sinks for maximum thermal conductivity in high-performance applications.
- Thermal Conductivity: 388 W/mK
- High-Power Electronics
- Superior Heat Transfer
Aluminum Heat Sinks
Lightweight aluminum solutions offering excellent thermal performance with cost-effective manufacturing.
- Thermal Conductivity: 167-180 W/mK
- Weight Optimization
- Cost-Effective Solution
Round Heat Sinks
Circular designs optimized for spot cooling and cylindrical heat sources with radial fin configurations.
- Diameter: 20-200mm
- Radial Fin Design
- Spot Cooling Applications
E-Coated Heat Sinks
Enhanced corrosion resistance with electrophoretic coating for harsh environment applications.
- Superior Corrosion Resistance
- Harsh Environment Suitable
- Automotive Grade Coating
Why Choose Cold Forged Heat Sinks?
Cold forged heat sinks offer significant performance advantages over traditional manufacturing methods, delivering superior thermal management solutions.
Performance Comparison
14% Better Than Extruded
Cold forged heat sinks demonstrate 14% improved thermal conductivity compared to traditional extruded alternatives.
62% Better Than Die Cast
Significant performance advantage over die cast heat sinks with 62% improvement in thermal efficiency.
Superior Surface Finish
Precision cold forging delivers exceptional surface quality without secondary machining operations.
Enhanced Thermal Performance
Superior thermal conductivity through dense material structure and optimized fin geometry.
Precision Tolerances
Achieve tight dimensional tolerances ±0.05mm without secondary operations.
Complex Geometries
Create intricate pin fin patterns and custom shapes impossible with other methods.
Cost Efficiency
Reduced material waste and elimination of secondary operations lower overall costs.
Cold Forged Heat Sink Applications
From high-power LED lighting to automotive electronics, our cold forged heat sinks deliver reliable thermal management across diverse industries and applications.
LED Lighting
High-power LED applications requiring efficient thermal management for optimal performance and longevity.
- • Street & Outdoor Lighting
- • Industrial High-Bay Fixtures
- • Automotive LED Headlights
- • Architectural Lighting
Automotive Electronics
Critical thermal management for automotive power electronics and control systems.
- • Electric Vehicle Inverters
- • Battery Management Systems
- • Power Conversion Units
- • Motor Control Electronics
Electronics Cooling
High-performance cooling for demanding electronic applications and power devices.
- • Power Semiconductor Devices
- • RF Power Amplifiers
- • Server & Datacenter Equipment
- • Industrial Control Systems
Telecommunications
Reliable thermal management for telecommunications infrastructure and equipment.
- • Base Station Equipment
- • Network Infrastructure
- • 5G Power Amplifiers
- • Optical Network Equipment
Renewable Energy
Thermal solutions for renewable energy systems and power conversion equipment.
- • Solar Inverters
- • Wind Power Electronics
- • Energy Storage Systems
- • Grid-Tie Equipment
Industrial Applications
Heavy-duty thermal management for industrial equipment and machinery.
- • Motor Drives & VFDs
- • Welding Equipment
- • Power Supplies
- • Industrial Automation
State-of-the-Art Manufacturing Equipment
Our advanced cold forging equipment and precision machinery ensure consistent quality and performance in every heat sink we manufacture.
Advanced Cold Forging Systems
Hydraulic Press Systems
400-ton capacity hydraulic presses with precision control for consistent forming results.
CNC Machining Centers
Multi-axis CNC equipment for precise finishing and secondary operations.
Quality Control Systems
Automated inspection and testing equipment ensuring consistent quality standards.
Material Options & Performance
Choose from premium aluminum and copper materials optimized for your specific thermal management requirements and application constraints.
Aluminum Heat Sinks
Thermal Conductivity
167-180 W/mK
Density
2.7 g/cm³
Key Advantages
- • Lightweight design for weight-sensitive applications
- • Excellent corrosion resistance
- • Cost-effective solution
- • Easy anodizing and surface treatments
- • Suitable for most thermal management needs
Alloy Options
- • Aluminum 1070 - High purity, maximum conductivity
- • Aluminum 6061 - Enhanced mechanical properties
- • Aluminum 6063 - Optimized for extrusion processes
Copper Heat Sinks
Thermal Conductivity
388 W/mK
Density
8.96 g/cm³
Key Advantages
- • Superior thermal conductivity (2.3x aluminum)
- • Ideal for high heat flux applications
- • Excellent electrical conductivity
- • Antimicrobial properties
- • Premium performance applications
Grade Options
- • C101 (99.99% pure) - Maximum thermal performance
- • C110 (99.9% pure) - High conductivity applications
- • C102 (Oxygen-free) - Electronic applications
Frequently Asked Questions
Get answers to common questions about cold forged heat sink manufacturing, specifications, and applications.
What are the main advantages of cold forged heat sinks over extruded alternatives?
Cold forged heat sinks offer 14% better thermal conductivity than extruded heat sinks and 62% better performance than die cast alternatives. The cold forging process creates denser material structure, tighter tolerances (±0.05mm), and enables complex geometries like pin fins with aspect ratios up to 50:1 that are impossible with extrusion.
Which materials are available for cold forged heat sinks?
We offer both aluminum and copper options. Aluminum alloys include 1070 (high purity), 6061 (enhanced strength), and 6063 (optimized formability). Copper grades include C101 (99.99% pure), C110 (99.9% pure), and C102 (oxygen-free) for different performance requirements. Aluminum offers lightweight and cost advantages, while copper provides superior thermal conductivity (388 W/mK vs 167-180 W/mK).
What is the typical lead time for custom cold forged heat sink production?
Lead times vary based on complexity and quantity. Standard designs typically require 2-3 weeks for prototyping and 4-6 weeks for production quantities. Custom tooling development adds 3-4 weeks to initial orders. We maintain inventory of common configurations for faster delivery and can expedite critical projects with our rapid prototyping capabilities.
What are the dimensional limitations for cold forged heat sinks?
Our cold forging capabilities accommodate base dimensions from 10mm x 10mm to 200mm x 200mm. Pin fin height can reach 50mm with diameters as small as 0.5mm. Minimum fin thickness is 0.25mm for aluminum and 0.3mm for copper. Maximum aspect ratios of 50:1 are achievable for pin fins, far exceeding capabilities of traditional manufacturing methods.
How do cold forged heat sinks perform in harsh environments?
Cold forged heat sinks excel in demanding environments. The dense material structure provides superior corrosion resistance. Optional surface treatments include anodizing (Type II/III), e-coating for automotive applications, nickel plating, and chromate conversion coatings. These treatments enable operation in temperatures from -40°C to +150°C with excellent humidity and salt spray resistance.
What quality standards and certifications do you maintain?
Our manufacturing facility maintains ISO 9001:2015 certification with full traceability and quality documentation. We comply with automotive standards including IATF 16949 for automotive applications, RoHS and REACH compliance for environmental requirements, and UL recognition for electrical safety applications. All materials come with certified mill test certificates and dimensional inspection reports.
Can you provide thermal analysis and design optimization services?
Yes, our engineering team provides comprehensive thermal analysis using CFD modeling, FEA simulation, and thermal testing. We optimize fin geometry, spacing, and configuration for your specific application requirements. Services include thermal resistance calculations, temperature mapping, airflow analysis, and design recommendations to maximize cooling performance within your constraints.
What secondary operations are available for cold forged heat sinks?
We offer complete secondary processing including CNC machining for mounting holes and custom features, drilling and tapping operations, surface treatments (anodizing, plating, coating), assembly with thermal interface materials, integration with heat pipes or vapor chambers, and custom packaging solutions. This ensures you receive a complete thermal management solution.
How do you ensure consistent quality across production runs?
Quality assurance includes incoming material inspection with certified test reports, process monitoring with statistical process control, dimensional verification using CMM and automated inspection systems, thermal testing and validation, and final inspection with comprehensive documentation. Each production lot includes material traceability, dimensional reports, and thermal performance validation.
What is the minimum order quantity for cold forged heat sinks?
Minimum order quantities depend on complexity and tooling requirements. For standard configurations, MOQ starts at 100 pieces. Custom designs typically require 500-1000 pieces due to tooling costs. However, we offer prototype quantities (5-50 pieces) for design validation and testing. Volume pricing incentives begin at 5,000 pieces with significant cost reductions for annual volumes exceeding 25,000 pieces.