Pros And Cons Of Different Types Heat Sinks
   How to select from an array of heat sink processes for optimal thermal performance

 
When it comes to design or develop electronic devices, computers, home applications or LED lights, thermal management is a key factor and heat sinks keep the device cool. How do we select from an array of heat sink processes, find the best fit for the devices and optimize its thermal performance? Today, we will dig in the Pros and Cons of different types of heat sinks.
 
Manufacturing process of heat sinks

Heat sinks are often classified by the manufacturing process. Aluminum, Copper are main materials for heat sinks, as well as bonded Aluminum / Copper (Al/Cu) heat sinks and Copper heat pipes. Seven processes are known as Extrusion, Cold Forging, Die Casting, Stamping, Bonded, CNC Machining, and Skiving. 
 

I. Extrusion is a process of forcing material rod into a die mold under high temperature, creating aluminum section material. Aluminum extrusion is widely used in various ranges due to aluminum’s unique physical characteristics; it provides the product with strength, ductility, and conductivity.

 
II. Cold Forging is a process that forms under high pressure and at room temperature. Forging heat sinks offer accurate dimension, strong surface and reliable structure and flexibility of a high aspect ratio for any fin type. Materials can be aluminium or copper.

 
III. Die-Casting is a process that inserts molten metal under high pressure into a mold cavity. It produces high structural integrity, smooth cast surface without secondary machinery operation.

 
 
IV. Stamping is the process of placing flat sheet metal into the desired form, producing light-weighted heat sinks, various ranges of shape and sizes in high productivity. It is widely used in PCB due to its minimal sizes.

 
V. Bonded is adapted for high power thermal solutions, individual fins bonded to base with thermal conductive epoxy and owns maximal flexibility in fin dimension of width and length.

 
VI. CNC Machining is a sophisticated process often deployed in the high precision level of mechanical parts; it is used to form the raw material in the desired shape and size, improved surface finish/coating and design.

VII. Skiving is carved out of a single block of metal to make an array of fine fins in specific shapes and sizes. Integrated base and fin structure minimize thermal cost in-between and enhance thermal conductivity as well as a lower development cost.

 
How to choose an appropriate heat sink type for your design?
 
Ø Cold Forging vs. Die-Casting Heat Sink
Cold forging tooling costs slightly more than die-casting because it needs to withstand tremendous force during production and generates high density and strength than die-casting.
Die- casting can be produced in more complex shapes than forging and in fast production rate and higher volume. However, if the part’s strength and durability are crucial, forging might be a better solution than die-casting. When debating between strength and durability rather than shapes, forging would be a better option than die-casting.
 

 
Ø Skiving vs. Extrusion Heat Sink

Extrusion and skiving are both an integral structure cause no thermal loss between the fins and the base. With extrusion, heat sinks can be made with aluminum only, while skiving heat sinks can be
made with alumiunm or copper at a lower development cost. For small quantity orders, skiving could be a better solution.
 

 
Ø Bonded vs Extrusion Heat Sink

Bonded heat sink can achieve up to aspect ratio of 45 in comparison to 22 of extruded heat sink, and with higher fins increase surface area and optimize heat dissipation, having more flexibility in material than extrusion. For higher power applications, bonded heat sink might be a good choice.
 

 
Zaward provides comprehensive product lines of thermal solutions. From DC/AC fan, diversified processes of heat sinks, to peripheral components such as heat pipes, fan guards, and thermal pads. We are always well prepared to solve any cooling issues with our best passion for customers worldwide.
For more product details, please feel free to visit our website. Any inquiries of thermal solutions are welcome. If you have any questions, please contact us.
 
 

 
With best regards, 
ZAWARD CORPORATION
 

 
Carmen Chen/ Managing Director