Online Catalog

Custom Heat Sink

Introduction for Custom Heat Sink

Introduction
Change fin height / base thickness
Change base size
Remove fins
Fin step cut
FSW(Friction Stir Welding)
Create holes / tapped holes
Embed copper plate
Pre-applied TIM / Tape
Attachment by push pins / springs
Attachment by Z-Clip / Anchors
Pre-Screen thermal grease
Surface Treatment Options
Assemblies
Variety of fin patterns/ geometry
Variety of accessory parts
Additional information
Display all

If our standard series heat sinks do not meet your needs, we can create custom heat sinks at a reasonable cost and lead-time. Please review the following guidelines regarding custom heat sinks.
There are two major custom design levels.

Typically, no tooling fees are required.
Suitable for low-mid quantity usage.
We can cut, drill, machine or wire EDM/EDM our existing
standard heat sinks.

Fin(pin) configuration, base size, and shape
options are almost unlimited.
Suitable for mid-high volume custom parts.

If you have any requests or opinions, please let us know.

Left:Standard Model W100-45W (Base thickness 7mm, Fin height 38mm)
Right: Customized (Base thickness 11, Fin height 34mm)

Left:Standard Model LPD60-10B (60x60x10mm)
Right: Customized base size (60x40x10mm)

* Fins would need to be removed if the base cut line crosses fins, or wire-EDM machining would be required.

Left:Standard Model UB60-10B
Middle: Heat Sink with fin removal
Right: Heat Sink with fin removal and mounting holes

It is possible to create a heat sink with multiple fin heights to deal with clearance issues. We can offer this feature as a step cut.

By using this process, standard heat sinks can be joined together to create larger sizes. This allows customers to obtain custom sizes with short lead times and small MOQs. In addition, by combining products with different fin patterns, optimal performance with regards to thermal resistance and pressure drop can be obtained.

Left:Standard Model LPD40-30B
Right: Customized ( Heat Sink with through holes)

* Note if interference with fins exists, the fins around the holes will be removed.

We can embed our heat sinks with a copper plate(heat spreader). The copper has a higher thermal conductivity, reducing spreading resistnace and increasing peformance.
Left: All aluminum Heat Sink
Right: Aluminum Heat Sink with a copper embedded base.

* The copper embedded surface cannot be anodized.

Our heat sinks are available with pre-applied thermal interface material or tape.
A variety of thermal interface materials/tapes are available and can be cut to any size.
Some thermal interface materials are available with a pull tab as shown on the heat sink on the left.

Attachment - Adhesive tape
Thermally conductive adhesive tape
Thermal tape/Grease

Heat sink is attached by push pins and springs. The PCB must have mounting holes.
A large combination of of push pins and springs are available to meet with almost any specification(PCB thickness, Chip size and target load).

Left:Heat sink with mounting tabs. LPDR35 - 15B
Right:Customized push pin heat sink from Standard Model LPD35 - 15B.

Attachment - Push pins

Heat sink is attached by Z-Clip. The PCB requires anchors.
Z clips and anchors can be purchased separately. Custom clips can be produced as well.

Attachment - Z-Clip
Z-Clip specification
Anchors

Heat Sinks can be shipped with pre-screened thermal grease. A protective cover will ship with the heat sink to prevent disturbing the grease during shipping.

Thermal tape/Grease

A variety of surface finishes/treatments are available.
(From Left) Black Anodize, Clear Anodize, Trivalent Chromate, No Surface Finish

Heat Sinks can be shipped as complete assemblies with subcomponents, including fans, mounting hardware, accessories, etc...

Virtually any fin shape or pattern is possible. Base size and shape is also very flexible.
With custom tooling, some feature, like prutrusion or recessed base areas can be created in the tooling, minimizing the amount of secondary machining.

Custom accessory parts, such as heat sink attachment hardware, can be quickly created.

Typically, the following modifications can be done without creating new tooling:

Height change
Base thickness change
Cut base size (by machining between fins or EDM cutting )
Fin removal (some fin patterns may be difficult to remove)
Holes/Tapped Holes (not interfere with fins)

Download our catalog parts drawing (DXF format) from our web site. Please feel free to contact us if you need assistnace or advice.

Custom tooling is warranted when there is no way to create the desired heat sink from our standard series. This would include fin pattern, base geometry, or features like threaded holes or standoffs. Tooling would also be warranted if a part could be made by machining an existing standard series, but is being used in high enough quantity to see a unit price reduction by tooling.

Once a part is tooled, secondary machine work as well as wasted material is minimized. Alpha will maintain the tooling for the life of production at no added cost. Also, many different heat sinks can be made from one tooling. The base thickness and overall height can be adjusted without having to modify the tooling. A 10, 20, and 35mm tall heat sink can all be made from the same tooling with no modifications required. (Please visit Heat Sink Design for MicroForging®)