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cold forging heatsink

Cold Forging Heatsink

Heatell is an expert manufacturer of heatsink in China. We offer high-quality heatsinks come from a cold forging process.

Heatell is capable of manufacturing excellent quality heatsink utilizing advanced manufacturing procedures like extruding, stamping, CNC machining, riveting, bonded fin, punching, skiving, dies casting, cold forging, etc.

As the leading manufacturer of cold forging heatsink, Heatell obtained trust from clients for supplying and manufacturing reliable heatsink products. We stocked hundreds of numerous cold forging heat sink to fully support your business.

Let Heatell skyrocket your business! Make a call now!

Your Reliable Cold Forging Heatsink Supplier and Manufacturer

Whether you’re a supplier, distributor, or custom factory that needs cold forging heatsink, then you are in the right place.

cold forged aluminum heat sink

Heatell is 8 years in providing cold forging heatsink to many industries worldwide.

Cold Forging Heat sink

Heatell cold forging heatsink production utilizing advanced production line, which is imported from Taiwan.

Cold Forging Heatsink

Our cold forging heatsinks using high purity copper and aluminum in the shape of pin coolers meet the requirements in an optimum way.

cold forging heatsink

Item TypeCold Forging Heatsink
Materialcopper/aluminum
Production ProcessCold Forging —Cutting—CNC Machining(Milling, Drilling, Tapping)—Deburring— Cleaning— Inspecting–Packing
Technicalextrusion, skived fin, stamping, cold forging, bonded fin, die-cast, liquid cold plates, folded fin
ApplicationLED Lighting, Inverter, Welding Machine, Communication Device, Power Supply Equipment, Electronic Industry, Thermoelectric Coolers/Generator, IGBT/UPS Cooling Systems, etc.
ThicknessBased on your requirements.
Film Thickness
Anodized: Customized. Normal thickness: 8 um-25um.
Powder Coating: Customized. Normal thickness: 60-120 um.
ColorSilver, black, white, bronze, champagne, green, gray, golden yellow, nickel, or customized.
FinishAnodizing, Mill finish, Electroplating, Polishing, Sand blasted, Powder coating, Silver plating, Brushed, Painted, PVDF etc.
Lengthcustomized length
Deep processCNC,drilling,milling,cutting,stamping,welding,bending,assembling,Custom Aluminum Fabrication
MOQLow MOQ
Packagingstandard export packaging or as discussed
CertificateCE/SGS/ISO/Rohs
Service1. Free sample, Free design;
2. OEM/ODM available;
3. Custom-made request;
4. New design solution suggestion
Delivery time15-20 days after sample confirmed & down payment, or negotiated
PortShanghai Port
Our Advantagesuperior quality with competitive price, Certified enterprises in China

We look forward to sharing expertise with you on your next project.

forged heat sinks

We have customer service technicians that are friendly, knowledgeable, and rich experience to support your heatsink business 24/7.

heat sink profile testing

-Standard Packing Option-

* Express Delivery*a
* Ocean Delivery*

-Loading & Shipment-

Heatell: Your Leading Cold Forging Heatsink Provider and Manufacturer with Best Price

Heatell cold forging heatsink is a good choice to have complex shapes with good thermal performance. As a leading manufacturing factory in China, Heatell is capable of manufacturing a wide range of heatsink comes from a cold forging process.

cold forging heat sink advantage

Through cold forging procedure, we can produce more fins per square meter because the fins are perfectly straight. When we say forging, it involves the shaping of metal. No wonder, Heatell cold forging heatsinks can be fabricated into different shapes. There are round pin heatsinks, plate-fin heatsinks, and elliptical fin heatsinks.

During the production of Heatell cold forging heatsink, there are secondary machining operations like chamfer, hole, and steps to reduce waste.

forged heat sink

Heatell is a well-experienced manufacturer in China, ensuring all cold forging heatsink uses a low temperature and high pressure. It guarantees no air bubbles or any other impurities trapped in our heatsinks.

Mostly, Heatell cold forging heatsink is constructed from C1100 or AL 6063. Here in Heatell, our cold forging heatsink is manufactured individually. Cold forging heatsink has a high aspect ratio up to 35:1, guaranteed no drafts angles are required.

Heatell manufacturing factory is your one-stop heatsink manufacturing solution. We are working in China for 8 years, specializing in the design, development, and manufacturing of all types of heatsink. Heatell is a leading supplier of cold forging heatsink, extruded heatsink, stacked fin heatsink, skived fin heatsinks, zipper fin heatsinks, bonded fin heatsinks, etc.

We are a specialist exporter and manufacturer cold forging heatsink has well-qualified technicians that can help in the entire production. If you choose to bear with us, we assure you to fully support your business. At Heatell, you are guaranteed satisfaction with our products and services.

Our friendly, reliable, and cooperative customer service is awaited you! Ask Heatell now for an instant quote.

Cold Forging Heat Sink: The Ultimate Guide

In this guide, you will find all information about cold forging heat sink.

Whether you want to learn about features, fabrication technique, benefits or surface finishing – you will find all information right here.

Take a look:

1.  What Is Cold Forged Heat Sinks?

Metal forging is a manufacturing method that transforms a shapeless or simple material into a structured heat sink.

The heat sink metal forging process creates a final product with well-defined size, shape, appearance, and properties without loss in mass or composition of the original material.

Specifically, cold forging heat sink refers to forming of material bulk at room temperature.

Cold forging excludes any initial or intermediate stage heating of the preform.

cold forged heat sink

cold forged heat sink

Subjecting the bulk heat sink material to high pressure controls the grain structure of the end product giving it superior thermal performance.

The process ensures the cold-formed heat sink are free of trapped air bubbles, impurities, and porosity. As a result, your cold-formed heat sinks are of exceptionally high quality and have excellent thermal conductivity.

2.  Benefits Of Cold Forging Heat Sink

Cold forging heat sink offers the following unique advantages which you can consider when selecting the appropriate technology for your thermal management.

Thermal Conductivity

Cold forged heatsinks possess superior thermal performance compared to other heatsinks fabricated following alternative methods such as die-casting, extrusion, machining, etc.

The cold forging delivers end products with a better-controlled grain structure.

Consequently, cold-forged heatsinks possess superior heat conduction to alternative types of heatsinks. For instance, a cold-forged heatsink has approximately 13% and 60% better thermal conductivity compared to heatsinks made by extrusion and die-casting, respectively.

Surface Area

You can increase the surface area of cold-forged heatsinks by approximately 18% without interfering with their weight or size.

Increasing the surface area of a heat sink yields better component cooling and lower thermal resistance. However, this is only true in the absence of boundary layers and where the distance between adjacent fans does not interfere with free airflow.

You can make almost perfectly straight or elliptical fins in cold-forged heatsinks which ensures that your heat sinks have maximum surface area.

Reduced Costs

The types and number of operations involved in the manufacture of a heat sink significantly determine the cost of production associated with the type of heatsink.

Unlike other alternative processes like die-casting and extrusion, cold forging does not require secondary machining for the construction of a finished product.

The lack of secondary operations in the cold-forging of heat sinks makes significantly reduces the cost of production and that of the final product.

There are fewer design limitations for complex cold-forged heat sinks compared to die-casting and extrusion.

You can create chamfers, holes, elliptical fins, pins, steps, etc. in a simplified single cold forging operation.

Versatility

You can produce fins with complex shapes such as staggered fins, elliptical fins, steps, round pins arrays, etc. with the cold forging tool.

In contrast, you cannot achieve these features in die-casting and extrusion.

Ideal For Copper Forming

Forming copper through extrusion is difficult and can be costly given that this material has to be subject to very high temperatures during extrusion.

In fact, higher temperatures can damage the extrusion tool.

Subjecting the part to secondary machining also yields excessive and expensive waste materials.

On the hand, you can easily form copper-based heat sinks through cold forging. The process also releases minimal waste compared to machining.

Other notable advantages of cold forging heatsink include;

  • Ideal for high rate, high volume production
  • Minimal waste release
  • The forging process hardens the strain yielding forged parts with a higher tensile strength than the original material.
  • Stronger forged parts as a result of favorable grain flow.
  • Lower energy consumption
  • Excellent surface finishing
  • Improved dimensional tolerance
  • Ease of bulk material combination
  • Short mold production cycle of only 10 to 15 days

3.  Applications Of Cold Forged Heat Sink

You can use cold forged heat sinks in diverse applications across many industries. However, the automobile industry is by far the leading consumer of cold-forged heat sinks.

You can also use cold forged parts in the manufacture of high-performance electronics, LED cooling, multi-chip modules, bicycles, motorcycles, machinery, nuts, bolts, etc.

More specifically, you can use a cold-forged heat sink to provide cooling solutions in:

  • Electric car controllers
  • Wind power converters
  • Energy storage systems
  • PV inverters

4.  Extruded Heat Sinks Vs Cold Forged Heat Sinks

Before choosing whether to go for extruded heat sinks or cold forged heat sinks, there are a number of factors you should know:

Extruded heat sinksCold Forged heat sink
Utilize high temperature in the formation processUtilize low temperature in the fabrication process
Can achieve an aspect ratio of approximately 22Technically can achieve an aspect ratio of up to 80, though optimal at 45
Lower heat conduction propertiesUp to 13% better heat conduction
Can be made with aluminum onlyCan be made with diverse metals
Impossible to increase fin surface area without increasing size and weightPossible to increase fin surface area without increasing size and weight

Extruded heat sink

Extruded heat sink

cold forged heat sink

cold forged heat sink

5.  Cold Forging Heat Sink Materials

You can construct a cold-forged heat sink with any metal that exhibits ductility at room temperature. Typically, aluminum, steel, copper, and their alloys are suitable materials for the fabrication of cold-forged heatsinks.

However, you can also use alloys of titanium, tin, beryllium, nickel, and zinc for specialized applications.

Some types of steel which you may consider for cold forging include:

  • Heat treatable steel such as 4130, 4140, 5140, 8620 alloyed steel, and 1020, 1035, and 1045 unalloyed steel.
  • Case hardening steel such as 3115, 5115,5120 alloyed and 1010, 1025 unalloyed.
  • Stainless steel including pearlitic (410, 430, 431) and austenitic (302, 304, 316, 321)

Though desirable, austenitic or austenitic-ferritic stainless steel is very difficult to cold forge and demands high tool pressure and force to work.

In addition, these materials are also very difficult to lubricate.

In the case of aluminum, you can consider the following for cold forging your heat sinks:

  • Pure or nearly pure alloys of aluminum such as 10250, 1070, 1100, and 1285.
  • Non-hardenable alloys of aluminum such as 303, 5052, and 5152.
  • Hardenable alloys of aluminum such as 2017, 2021,6053,6063,6066, and 7075.

Pure aluminum is ideal for high-performance heat sinks given that it offers the highest thermal conductivity among aluminum materials.

You can acquire these materials in the form of wire, drawn or rolled rods, and sawed-off or sheared billets.

You should carefully control the dimension, surface finishing, and weight preform or sheared/sawed billet to maintain the cold-forged part’s dimension tolerance.

This is also necessary for the reduction of loading of forging tooling and press.

6.  Die Cast Heat Sink Vs Cold Forged Heat Sinks

Die-cast heat sink and cold forge heat sin compare as follows:

Cold Forged Heat SinkDie Cast Heat Sink
Fabricates a heat sink forms parts by subjecting the bulk metal to high pressure at low temperatureFabricates parts by inserting molten metal into a mold cavity under a high pressure
More expensive due to more force used in its productionLess costly
The shapes are limited compared to die-castingSupports the production of more complex shapes
Production throughput is lower compared to die-castingSupports higher production rates and volumes
Superior thermal performance/thermal conductivity and heat dissipationLower thermal management capabilities to die-casting
Produces stronger parts than die-castingLess strong parts to die-casting.

Die cast heat sink

Die cast heat sink

7.  Cold Forging Heat Sink Vs Machining Heat Sink

Here is how these two heat sinks compare;

Cold Forged heat sinkMachining
Possess superior thermal conductivityLower thermal conductivity
Can support high aspect ratioLower aspect ratio
No gaps between base and fins thus less thermal resistanceHas gaps between base and fins thus higher thermal resistance
Possible to construct fins of limitless shapesThe design of fin shapes is limited
Possible to increase fin surface area without increasing size and weightIncreasing fin surface area corresponds to increased size and weight
Produce fewer wastesProduce more wastes
No need for secondary machining thus lowering the cost of productionNeed for secondary machining thus higher cost of production
Ideal for high volume, high rate of productionIdeal for construction of prototypes, too expensive for high volume, high rate of production

machining heat sink

machining heat sink

8.  Features Of Cold Forged Heat Sinks

A cold-forged heatsink possesses the following key features:

Superior Thermal Conductivity

Cold forged heatsinks offer better thermal management options compared to heat sinks fabricated either through die-casting, extrusion, or machining.

The cold forging process considerably increases the thermal conductivity of the finished product compared to the bulk material.

This is achieved through better control of the grain structure as a result of pressurized compaction of the bulk material in the process of cold forging.

The cold-forged part possesses better thermal conductivity, ascertaining faster heat release and superior thermal performance.

Superior Heat Dissipation Structure

Cold forged heat sink possesses superior heat dissipation compared to heat sinks fabricated through other methods.

Heat sinks fabricated through machining and brazing have gaps between the fins and base plates.

The gaps cause indirect thermal resistance and enlarge following subsequent contraction and expansion during lamp operation, thus increasing thermal resistance.

In contrast, the sink and base plate of a cold-forged heat sink are formed integrally without any gaps. Hence, there is no thermal resistance due to the existence of a gap.

Product-specific Structure

The cold forging process can form the top and bottom of base-plate specific structures as well as the lateral surface.

This offers the cold-forged heat sink an exceptional connection to the heat elements.

Larger Cooling Area

You can optimize fin placements in cold-forged heatsinks to ensure the availability of maximum surface area for cooling.

It is possible to design your cold forged heat sinks with 0.7 MM thick fins spaced at 1MM between each other.

The corresponding fin density and thinness significantly yield optimal air contact area and deliver superior air convection cooling.

Diverse Fins

Cold forging heat sinks offer an assortment of fin shapes to select from.

Among the side diversity, you can consider thin sheet shape, cylindrical shape, hexagonal columns, square columns, etc.

Large Size Heat Sinks

Cold forging technology offers limitless dimensional access which may be limited in other alternative technologies.

You can design and fabricate heat sinks with extensive dimensions as large as 200mm * 250mm and beyond.

High Aspect Ratio

Heat sinks fabricated following cold forging technology offer almost double the aspect ratio achievable in extrusion fabricated heat sinks.

In a cold-forged heat sink, aspect ratios as high as 1:50 are easily attainable while the extrusion process can only deliver aspect ratios averaging about 1:25.

Multi-direction Air Cooling

Cold forged heat sinks support a three-dimensional air cooling, unlike extrusion-based heat sinks which only support two-dimension airflow.

The multi-dimensional air flow characterized by a cold-forged heat sink adds to its excellence in thermal management.

It can also be used in diverse environments, thanks to its superior environmental adaptation capabilities.

Lighter Weight And Smaller Volumes

You can use cold forged heat sinks in a diverse assortment of applications because they deliver better thermal management and are also lighter and smaller.

You can cold-forged heat sinks in bigger power electronic devices with similar shape and volume offered by machining, die-casting, and part soldering.

Their use in such applications considerably contributes to a significant reduction in equipment volume and weight.

In addition, it will also offer optimal appearance design requirements, and deliver optimal product competitiveness in the market at a lower cost.

Appearance

Depending on the type of material used, you can apply anodized surface treatment for aesthetic appearance and cleanliness.

The finished product has a smooth surface unlike heatsinks made from die-casting which have rough surfaces.

In fact, the die-casted heat sink will require that you further subject the parts to spraying, which is also less conducive for heat dispersion.

Technology Characteristics

At the moment, a cold-forged heat sink offers the best thermal performance for high-power electronic devices.

It is more stable and possesses higher dimensional accuracy compared to alternative types of heat sinks.

By comparison, cold-forged heat sinks rate two times and one time higher than similar types of die-casted and extruded parts, respectively.

9.  Common Shapes Of Cold Forged Heat Sink

Round Pin Heat Sink

The round pin heat sinks support omnidirectional airflow, that is, air can flow into the heatsink from any direction.

Round pin heatsinks create more turbulence when air blows through them, thus increasing the efficiency of cooling.

round pin heat sink

round pin heat sink

A change in direction or speed of the flow of air has minimal impact on the heatsink performance.

The pressure drop is significantly reduced in round pin heat sinks compared to square-shaped pins, translating into increased airflow over downstream components.

Elliptical Pin Heat Sink

Elliptically shaped pin heat sinks deliver exceptional thermal performance if your system has excellent airflow.

They also support Omni-directional airflow and record a very low impact on thermal performance in case of a change of speed or direction in the flow of air.

They support even lower pressure drop compared to round pin heatsinks which translate into exceptional heat transfer in the entire system.

Elliptical heat sink

elliptical heat sink

They will outperform round pin fins even when the latter is made of a material with a better heat dissipation feature.

10.  Surface Finishing For Cold Forged Heat Sink

Surface finishes for cold forged heat sinks protect them from hazardous environmental conditions.

The most common surface finishing techniques that you can consider for cold forged heat sinks include:

  • Anodizing
  • Chromate finishing
  • Tin/Led finishing
  • Electroless Nickel
  • Mechanical finishing
  • Painting
  • Powder Coating

11.  Passive Vs Active Cold Forged Heat Sink

Passive cold forged heat sinks are heat sinks that naturally conduct heat away from the target regions in a component or device without any further assistance.

passive cold forged heat sink

passive cold forged heat sink

Generally, they’re larger and less expensive compared to active heat sinks. You also have to provide a large clearance in the surrounding point of attachment.

In contrast, an active cold forged heat sink has an attached powered component such as water pumps or fans that helps fasten the rate of heat transfer.

The most widely used example is a cold-forged heat sink with a single or several fans attached to its metal fins.

The fans push/pulls air into and out of the heat sink, fastening the rate of heat dissipation in the process.

12.  Design Considerations For Micro Forming Cold Forged Heat Sink?

In designing a cold-forged heat sink, the following key considerations will ensure the formation of a high-quality heat sink that is desirable for a wide range of high-performance applications.

Material

Material selection is dependent on the corresponding type of component/application that the cold-forged heat sink will be mounted in.

Aluminum is one of the most used and offers striking benefits such as lightweight and high thermal conductivity.

Fin Height

You can manufacture fin heights that are 50 times longer than the fin thickness.

Though you could technically fabricate fins that are up to 80 times longer than their thickness, doing so will reduce the rate of increase in operational efficiency.

The optimal fin height is approximately 45 times longer than its width when cost and performance factors are taken into consideration.

Cross-section Of The Fin

The shape of the fin’s cross-section can vary from a square, round, hexagonal, elliptical, to any other feasible shape desirable for a given application.

Fin Distribution

Normally, the fin should be distributed evenly on the heat sink’s plates.

However, you could also delete some fins in a section of the base as desirable for a specific application. The distribution can also gradually change along the base.

Shape Base

The base of your cold forged heat sinks can vary in shape from circular, rectangular, square, and even to irregular shapes.

Reduction Ratio Of The Cross-section

The cross-section reduction ratio refers to the proportion between the base total area to its finless area.

You can compute the cross-section reduction ratio by using the formula; (Total base area – Total fin area)/ (Total base area).

You can multiply the result with 100 to express it as a percentage.

Generally, the cross-sectional reduction ratio of your cold forged heat sink should vary from 75% to 85% with the exception of heat sinks fabricated for natural heat dissipation.

Heat Treatment

Though not a prerequisite, you could also heat-treat your cold forged heat sink if strength was a desirable property.

13.  Increasing Efficiency Of Cold Forged Heat Sink

You can increase the efficiency of a cold-forged heat sink by considering the following:

  • Selecting a material with high thermal conductivity such as copper or diamond
  • Optimizing the heat sink fin consideration such as to offer minimal flow resistance. Ensure that your design offers the ideal placement of heat sink fins.
  • Maintaining a low aspect ratio for the fins.
  • Reducing the surface roughness of the heat sink and increasing its interface pressure.

Use thermal interface material in case of limitations to resistance reduction methods.

  • Optimizing the heat sink’s attachment method to an electronic device/component.
  • Optimizing the heat sink to enable maximum dissipation by analyzing diverse heat sink designs that support minimal thermal resistance.

More Resources:

Heat Sink

Heat Sink Size Calculator

Improving Power Density In Heat Sinks

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