Custom Heat Pipes

Custom Heat Pipe

Heat pipes are initially manufactured in round shapes, but can be customized through a series of bending and flattening processes to form 2D or 3D shapes. Customized heat pipes can transfer heat from the source to almost anywhere that the design requires. Examples of thermal solutions using custom heat pipes can be found on this page.

What We Can Manufacture

For custom copper heat pipes, we can produce different diameters and lengths. Most common diameters are 4mm, 5mm, 6mm, 8mm, and 10mm. Lengths can also range from 80mm to 600mm. Working fluids can either by H20 distilled water or CH3OH methanol. For surface finishes, we offer anti-oxidation and nickel plating. Nickel plated finishes are great for soldering heat pipes to aluminum parts.

Rapid Prototyping of Custom Heat Pipes

We offer rapid prototyping services for custom heat pipes. If tooling is not required, the prototypes can be made within 2 business days. For parts that require special tooling, the turnaround time is 5 business days. Please contact us for more information.

Super Thin Heat Pipes for Smart Phones and Mobile Devices

Super Thin Heat Pipe for Smart Phone, Laptops and Tablets

We make heat pipes that are as thin as 1.0 mm (0.040″), which can be used on smart phones, laptop computers, tablets and other miniature electronic devices. The heat pipes are 100% individually tested to ensure heat transfer efficiency. Other thicknesses including 1.2 mm, 1.5 mm, 1.6 mm and 1.8 mm are also available.

Working Fluids

For custom heat pipe designs, we offer two types of working fluids: H20 Distilled Water and CH3OH Methanol. H20 Distilled Water is best for above-room temperature (20°C) applications with operating temperatures of 1°C to 325°C. CH3OH Methanol is best for low-temperature applications with operating temperatures of -75°C to 120°C. Methanol is best for low-temperature application since it does not freeze as easily as water.

Bending of Heat Pipes

Bending of Heat Pipes

To minimize the impact on thermal performance, we recommend the following bending radii and angles as the design guidelines.

DiameterMinimum RSuggested RMinimum
Bending Angle
Suggested
Bending Angle
4 mm9 mm12 mm90 °120 °
5 mm12 mm15 mm90 °120 °
6 mm14 mm18 mm90 °120 °
8 mm20 mm24 mm90 °120 °

To make sure custom bent heat pipes are manufacturable, the minimum inner radius needs to be at least 2x the diameter of the heat pipe. The Qmax will reduce by about 2.5% for every 45-degree bend. The performance of the heat pipe will decrease by about 20% after the first bend, and then down by 10% for each additional bend.

Flattening of Heat Pipes

Flattening of Heat Pipes

The following table provides a guideline for the flattening of heat pipes. For diameters and thicknesses not listed in this table, please contact us.

Diameter (D)Thickness (T)(T) ToleranceWidth (W)(W) Tolerance
Ø42.0+0.05/-0.105.23+/-0.15
Ø42.5+0.05/-0.104.96+/-0.15
Ø43.0+0.05/-0.104.65+/-0.15
Ø52.0+0.05/-0.106.82+/-0.15
Ø52.5+0.05/-0.106.53+/-0.15
Ø53.0+0.05/-0.106.26+/-0.15
Ø53.5+0.05/-0.105.95+/-0.15
Ø54.0+0.05/-0.105.63+/-0.15
Ø62.0+0.05/-0.108.45+/-0.15
Ø62.5+0.05/-0.108.16+/-0.15
Ø63.0+0.05/-0.107.84+/-0.15
Ø63.5+0.05/-0.107.57+/-0.15
Ø64.0+0.05/-0.107.30+/-0.15
Ø82.0+0.05/-0.1011.65+/-0.15
Ø82.5+0.05/-0.1011.39+/-0.15
Ø83.0+0.05/-0.1011.15+/-0.15
Ø83.5+0.05/-0.1010.83+/-0.15
Ø84.0+0.05/-0.1010.60+/-0.15
Ø84.5+0.05/-0.1010.27+/-0.15
Ø85.0+0.05/-0.1010.01+/-0.15
Ø86.0+0.05/-0.109.36+/-0.15

To Calculate Width

W = (D-T) * 0.666+D

W = Width of Heat Pipe
D = Diameter of Heat Pipe
T = Thickness of Heat Pipe (when flattened)

After flattening, heat pipes cannot by bent out-of-plane (no exceptions). Heat pipes can only be bent out-of-plane when the heat pipe is round.

Heat Transfer Capability

Heat Pipe ShapeCross-sectional
Dimensions
(mm)
Length
(mm)
Minimum
Bending Radius
(mm)
Heat Transfer Rate
(L=150mm)
(W)
Round PipeØ460-6001030
Round PipeØ560-6001045
Round PipeØ660-6001272
Round PipeØ860-60024120
Flattened PipeØ4 X 2.0T60-6001025
Flattened PipeØ5 X 2.0T60-6001031
Flattened PipeØ6 X 2.0T60-6001242
Flattened PipeØ8 X 2.0T60-6002555

Reliability Test

No.Test ItemTest ConditionsSampling RatioPurpose
1High Temp. Aging TestAmbient Temp. 210 C for 12 hr100%Leakage check & aging
2Thermal Response TestInsert 1/3 – ½ length of pipe into 50°C water. The temp of other end shall rise to standard value in 25 seconds.100%Vacuum & leakage check
3Qmax TestHeating Length = 25-35mm, Test temp = 60°C100%To measure the max. heat transfer rate
4Rth Thermal Resistance TestFix heat transfer rate and measure temp. difference of heat pipes>1pcs/2hrTo ensure thermal resistance of each pipe be lower than spec
5Accelerated Life Test140 C for 1000hr. Performance decrease by less than 7%By caseTo predict life of heat pipe at certain operating temp.
6Continuous Life TestContinuous testing at normal operating conditionsBy caseTo measure actual life of heat pipe until failure occurs
7Thermal Cycling TestTemp. varies from -30 C to 120 C in 10hr, 600 cyclesBy caseTo measure performance variation after thermal cycling

Heat Pipe Assembly

With custom heat pipes, we also offer heat pipe assemblies. Please visit our Heat Pipe Assembly Design page for more info.

Request information or quote of custom heat pipe

    Desired Diameter (4, 5, 6, 8, 10, 12 mm)

    Desired Length (80-500 mm)

    Power to Dissipate (watts, optional)

    Ambient Temperature (optional)

    Desired Shape (round/flattened/bent/custom)

    You may upload a drawing or image

    Quantity to Quote (e.g. 200, 1K, 20K, 100K)

    Other Requirements/Comments

    Your Name *

    Job Title

    Company Name *

    Company Address

    Email Address *

    Phone Number *

    © 2021 MyHeatSinks, Inc. All Rights Reserved.