Skived Heat Sinks
Skived heat sinks are produced by shaving and lifting thin layers of copper or aluminum with a precision blade to form fins directly from the base, creating a single-piece structure with excellent thermal conductivity. Their ultra-thin fins, high aspect ratios, and dense fin arrays maximize surface area within limited space, delivering superior thermal performance. The process requires minimal tooling, supports both prototypes and production runs, and allows further customization through CNC machining, surface finishing, or heat pipe integration. MyHeatSinks offers skived heat sinks manufactured in the USA or China, providing flexibility for domestic and global sourcing.
Cold Forged Heat Sinks
Cold forging is a highly efficient manufacturing process for producing pin-fin heat sinks. The process involves shaping a workpiece at room temperature under extremely high pressure, typically taking 15-20 seconds to forge an average heat sink. The combination of high pressure and low temperature ensures not only dimensional accuracy but also the absence of air bubbles, porosity, or impurities in the material. As a result, cold-forged heat sinks exhibit exceptionally high quality.
Extruded Heat Sinks
Extrusion is one of the most cost-effective manufacturing methods for producing plate fin and cross-cut heat sinks. It stands out for its low tooling and unit costs, making it an economical choice for mass production.
Die-Cast Heat Sinks
Die casting is a highly efficient manufacturing process that can produce parts with complex shapes. With die casting, heat sink fins can be incorporated into a frame, housing or enclosure, so heat can be transferred directly from the source to the environment without additional resistance. When used to its full potential, die casting provides not only excellent thermal performance, but also significant savings in cost.
Machined Heat Sinks
CNC (Computer Numerical Control) machining and EDM (Electrical Discharge Machining) are highly accurate, do not require tooling, and offer short lead times, making them ideal for the prototyping phase and for manufacturing complex heat sinks that other methods cannot achieve.
Stamped Heat Sinks
Progressive die stamping is a metal forming process where a continuous strip of metal, like aluminum or copper, is fed through a series of stations in a single automated machine. Each station performs a specific operation — cutting, bending, or forming — to progressively shape the metal into the desired component. In heat sink manufacturing, this process creates thin, precisely shaped fins that are stacked and interlocked into a complete fin set.
Stir-Welded Heat Sinks
Friction Stir Welding (FSW) is a solid-state joining process that uses frictional heat generated by a rotating tool to soften and join two pieces of material without melting them. This process creates a high-strength bond between the materials. It is particularly advantageous when manufacturing large heat sinks that otherwise require expensive tooling. It offers a cost-effective alternative for small to medium-sized orders. By weighing the tooling costs against the welding costs, customers can determine the most economical approach for their specific needs.
Heat Sinks Made in USA
MyHeatSinks is increasing manufacturing capabilities in the U.S.. Our U.S. facility is positioned to manufacture high-performance heat sinks with state-of-the-art technologies, including copper and aluminum skiving, five-axis machining, solder reflow systems, robotic systems, EDM and horizontal milling.
Heat Sink Design Assistance
We can provide customers with thermal design assistance. The service includes thermal analysis using simulation software, heat sink design and optimization, manufacturability review, GD&T review, and material analysis.