Custom Heat Sink Manufacturing

From rapid prototyping to high-volume production, we transform complex thermal challenges into high-performance cooling realities.

A custom heatsink is designed to your device’s specifications, ensuring optimal thermal management. By considering factors such as the device’s power dissipation, airflow, and space constraints, we can create a heatsink that maximizes heat dissipation and minimizes the risk of overheating.

With our depth of expertise, we can manufacture custom heat sinks. We collaborate closely with our clients to understand their distinct requirements and precisely manufacture customized heat sinks that uniquely fit their devices. Whether you need a heatsink for a computer processor, power electronics, or any other application, we have the expertise to deliver exceptional results.

Getzshape Custom Heat Sink Manufacturing

Processes for Heat SInk

A variety of manufacturing processes are suitable for heat sink production. Currently, the mainstream methods for structural fabrication are CNC machining and skiving. Both offer significant advantages in production efficiency and cost-effectiveness, particularly for medium-to-large-scale heat sinks. However, for ultra-thin fin heat sinks—reaching thicknesses as low as 0.1 mm,（metal) 3D printing is required.

Custom Milled Heat Sink

Computer Numerical Control machining. This involves using high-precision cutting tools to carve the heat sink from a solid billet. It is typically reserved for high-precision prototypes or extremely complex geometries where tooling for other methods is not feasible.

Custom Extruded Heat Sink

The most cost-effective and widely used method. Molten aluminum is pushed through a steel die to create long spans of constant cross-section (finned profiles), which are then cut to length.

Custom Die Cast Heat Sink

Molten metal is injected into a mold under high pressure. This process is ideal for complex, three-dimensional shapes that cannot be achieved through extrusion, though it often results in lower thermal conductivity due to the alloys used.

Custom Skived Heat Sink

A process where fins are “shaved” or sliced directly from a solid block of metal (usually copper or aluminum) and then bent upright. This creates a seamless interface between the base and the fins, offering excellent thermal performance.

Custom Stamped Heat Sink

Individual fins are stamped and then bonded, soldered, or swaged onto a base. Fins are stamped with interlocking features that allow them to be “zipped” together into a dense fin pack. This is common in high-end CPU coolers and heat pipe assemblies.

Heat Sink Materials

A heat sink is a thermal management component designed to dissipate heat from heat-prone electronic devices. Typically fabricated from aluminum alloy, brass, or bronze, it is manufactured in various configurations, including plates, sheets, or multi-finned structures.

Custom Aluminum Heat Sinks

Aluminum’s exceptional extrudability enables the fabrication of complex, high-aspect-ratio fin profiles that maximize surface area while maintaining lightweight properties. Its high thermal conductivity, combined with excellent corrosion resistance, ensures long-term reliability even under rigorous thermal cycling. Available high-performance grades include 1060, 6061 and 6063.

Custom Copper Heat Sinks

Copper’s exceptional thermal conductivity makes it the premier choice for heat sink fabrication, offering unparalleled heat dissipation efficiency compared to other metals. When utilized in skived fin or stacked fin assemblies, copper enables extremely dense fin structures, maximizing surface area within compact footprints. While denser than aluminum, its better heat transfer capability is vital for high-power electronics and extreme thermal loads. Available grades include C11000 and C10100.

Anodizing

Building a strong layer that helps aluminum parts resist wear and tear. It enhances the material’s surface and is available in different color options.

Powder Coating

Dry powder coating baked onto aluminum for tough, colorful finish. Dry powder coating baked onto aluminum for tough, colorful finish.

Painting

Giving products a great finish and strength. It provides a colorful surface that protects the metal from environmental damage and friction.

Electroplating

Use electrolysis to deposit a layer of metal or alloy onto the surface of a workpiece.

Brushed

Mechanical polishing that produces a unidirectional satin finish.

Heat Sink Specifications

Items	Features
Processes	Aluminum Extrusion, Die Casting, Skiving, CNC Machining, Stamping
Tolerance	Dimensional Tolerance: 0.1mm Surface Roughness: Ra 3.2 CNC Machining Flatness: 0.05mm
Surface Finish	Sand blasting, Brushed, Painted, Anodizing, Electroplating
Dimensional Features	Maximum Sizes: 500 mm (L) * 400 mm (W) Base Plate Thickness: 0–50mm Fin Thickness: > 0.5mm Fin Aspect Ratio (Height-to-Gap): < 25:1

A heat sink is a cooling component designed to dissipate heat from heat-prone electronic devices. Typically fabricated from aluminum alloy, brass, or bronze into plates, fins, or multi-finned structures, it functions by spreading heat from the source onto high-surface-area fins. This thermal energy is then transferred to the surrounding air via conduction and convection.

During installation, a layer of thermal grease (thermal interface material) must be applied to the contact interface between the electronic component and the heat sink. This ensures that heat is efficiently conducted to the heat sink by eliminating air gaps before being dissipated into the ambient environment.

What is Heat Sink？

The heat sink is tasked with dissipating heat generated by components into the surrounding air, serving as the primary thermal conduction pathway within air-cooling systems. Its core functions include: