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die cast heat sink

Die Cast Heat Sink

Heatell is a professional manufacturer of die-cast heat sinks in China for over 8 years. We stocked thousands of die-cast heat sink to help your business grow. We can help you in your die-cast heat sink product from initial idea and design, material samples and prototyping, to manufacturing and fabrication.

We can custom die-cast heat sink design for your unique assembly and delivery needs. Experience world-class service and highest quality die-cast heat sink only in Heatell!

Send us your requirements, our expert team will offer to die-cast heat sink design solutions with cost-effective manufacturing.

Your Premier Die Cast Heat Sink Manufacturer and Supplier

Heatell is a dedicated team, willing to help you innovate thermal management solutions and systems.

aluminum Die Cast Heat Sink

At Heatell, we are your technically-advanced problem solver. We own an advanced production line and utilizing vast knowledge in manufacturing die-cast heat sink.

die cast heat sink

Are you in need of a die-cast heat sink for your project or business? Heatell is the best choice to work with your die-cast heat sink orders.

heat sink casting

Heatell is a professional die-cast heat sink manufacturer in China, offering reliable solutions for your die-cast heat sink. We owned a state-of-the-art production line to offer reliable die-cast heat sink and no-cost thermal design services.

Die Casting Heat sink

Heatell is not just an established die-cast heat sink manufacturer, but your OEM manufacturer for your branding! As a leading die-cast heat sink manufacturer and supplier, we can help you fully support your business with our all-in techniques.

Item TypeDie Cast Heat Sink
MaterialAluminum alloy ADC12, ADC10, A360, A380, A356, etc
Magnesium alloy AZ91D, AM60B
Zinc alloy ZA3#,ZA5#,ZA8#
ShapesBased on your requirements.
Lengthcustomized length
Technicalextrusion, skived fin, stamping, cold forging, bonded fin, die cast, liquid cold plates, folded fin
ApplicationPrecision metal parts and components / Computer Peripherals / Consumer Electrical Components / Medical / Industrial Components /
Telecommunications / Automotive / Lighting components / Furniture components etc.
FinishAnodizing, Mill finish, Electroplating, Polishing, Sand blasted, Powder coating, Silver plating, Brushed, Painted, PVDF etc.
Deep processCNC,drilling,milling,cutting,stamping,welding,bending,assembling,Custom Aluminum Fabrication
Packagingstandard export packaging or as discussed
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

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heat sink effect

-Standard Packing Option-

* Express Delivery*
* Ocean Delivery*

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Heatell: Your Reliable Die Cast Heat Sink Provider in China

If your application requires complex geometries or outstanding cosmetic surface quality, then Heatell die-cast heat sink is an ideal choice. Heatell is a company of experts, specializing in the design, development, and manufacturing of die-cast heat sink.

die cast heat sink

Heatell die-cast heat sink is manufactured from aluminum 380 and aluminum 413. This kind of heat sink is used for different electronic devices and components. In fact, most suppliers, companies, and individuals worldwide prefer Heatell die-cast heat sink.

heat sink profile testing

Our Heatell die-cast heat sink has a big role to play in circuit boards (PC boards), high-powered lasers, fixtures, housings & LED, audio equipment, automotive equipment, communication equipment (cellular and satellite devices), etc.

die cast heat sink die cast heat sink

Die-cast heat sink manufacturer and supplier guarantees reliable performance heat sink and brings limitless advantages and features to your applications. Generally, they are electrically grounded. Our team ensures a robust die-cast heat sink and can be molded with many features.

Heat Sink manufacturer

Heatell die-cast heat sink is specially designed for extracting heat from components. Unlike other procedures such as machined heat sinks or extruded heat sinks, Heatell die-cast heat sinks need less machining.

Here in Heatell, you can avail of our die-cast heat sink in many powder-coated or anodized. You can also order a die-cast heat sink without any finish. However, powder-coated or anodized die-cast heat sinks provide corrosion resistance and improved surface protection. A customized die-cast heat sink is imperishable in Heatell.

Heatell wants to be your go-to heat sink manufacturer and supplier. As one of the leading die-cast heat sinks manufacturers in China, Heatell can produce and design custom and standard die-cast heat sinks for your specific applications.

Contact us now!

Die Cast Heat Sink: The Ultimate Guide

If you are looking for any information about die cast heat sink, then this is the right place for you.

Here, you will find all information you are looking for about die cast heat sink such as design, features, fabrication process, material type and surface finishing, just to mention a few.

So keep reading to learn more.

1.  What Is Die Cast Heat Sink?

A heat sink is a component that absorbs excess or unwanted heat.

Alternatively, a heat sink can be defined as device that increases the heat flow away from a hot device.

Heat sinks are core components in thermal management of various systems, be it electronic or mechanical systems.

Die cast heat sink

Die cast heat sink

Heat sinks can be manufactured through a number of methods including forging, extrusion, stamping, and casting.

As such, a die cast heat sink is a heat sink manufactured through the die casting process. Conclusively, the name of the heat sink is derived from the manufacturing method.

For better understanding, die casting is the process of forcing hot metal through a mould cavity.

2.  Advantages Of Die Cast Heat Sink

Die cast heat sinks are economical since there are no raw materials that are wasted.

Die cast heat sinks have a number of benefits that make them preferred. These include:

Producing heat sinks through die casting is characterised by high production rate

The final product is complete and does not require secondary machining. Lack of machining translates to time and cost-saving in the manufacturing process.

Die cast heat sinks have a high to moderate corrosion resistance rate.

With die casting, you can combine all the elements of the heat sink in a single casting cycle.

Die casting allows for production of complex 3D shaped heat sinks; which is not possible through extrusion or forging.

It is possible to core holes in die cast heat sinks.

Lastly, die cast heat sinks have superb Electromagnetic Interference (EMI) and Radio Frequency Interference (RFI) shields.

This feature minimizes the probability of malfunction by blocking both internal and external electromagnetic waves.

3.  Die Cast Heat Sink Vs Extrusion Heat Sink

Die casting, extrusion, and forging are the main methods used in the manufacture of heat sinks.

In this section we will focus on die cast and extrusion heat sinks to bring out a clear difference.

Extrusion Heat Sink.

Arguably, extrusion is the most common method used in the manufacture of heat sinks since it is relatively simple.

Generally, extrusion heat sinks have a uniform cross-section throughout the entire length and section. Consequently, extrusion heat sinks are not complex.

Extrusion heat sink

Extrusion heat sink

In extrusion, a lot of precision has to be made in coming up with the aspect ratio and the density of the heat sink’s fin.

Die Cast Heat Sink

Die cast heat sinks are mostly complex and include examples such as industrial heat sinks and notebook chip heat sinks.

Despite having low processing costs, the die casting molds for the heat sinks are relatively expensive.

Also, the material used in the manufacture of die cast heat sinks usually has a lower thermal conductivity than the one used in the extrusion heat sink.

Die cast heat sink

Die cast heat sink

For example, extrusion heat sink uses AL6063 (with thermal conductivity of 200W/mK) while die cast heat sinks to use ADC12 (with thermal conductivity of around 96W/mK).

Conclusively, die cast heat sinks and extrusion heat sinks differ as below:

Method Of Production

Manufacture of extrusion heat sinks involves heating the raw material.

This is just before the boiling point and then squeezing/extruding it through a medium to create the heat sink.

On the other hand, die cast heat sinks are produced by injecting the raw material into a die, forming the heat sink.

Economic Aspect (Left Overs)

Extrusion heat sinks result in raw material wastage since any material cut away from the heat sink cannot be reused.

However, in the manufacture of die cast heat sinks, the excess material is usually remelted and used for other parts.


Dies casting allows for the inclusion of special features and mounting holes into the heat sink.

Hence, no need for machining.

On the flip side, extrusion heat sinks need further machining to add extra features and mounting holes.

4.  Aluminum Die Casting Heat Sink Vs Die Cast Zinc Heat Sink

Both zinc and aluminum are used in the manufacture of die casting. Nonetheless, aluminum is widely used for several reasons.

We will look at the two materials, considering their pros and cons.

Aluminum Die Cast Heat Sink

Aluminum is most preferred in the manufacture of heat sinks due to its thermal conductivity, weight, and electrical conductivity.

Although aluminum die cast heat sinks are lightweight, they still have good thermal and electrical conductivity.

This doesn’t mean that aluminum has the highest thermal or electrical conductivity. However, the weight and conductivity combination makes it stand out.

Aluminum die cast heat sink

Aluminum die cast heat sink

Zinc Die Cast Heat Sinks

Compared to aluminum, zinc is stronger and tougher. This can be attributed to the heavier weight of zinc.

It is also easier and cheaper to die cast zinc heat sinks.

Aluminum heat sinks outshine their zinc counterparts regarding thermal conductivity and weight. But, if you want your die cast heat sink to get that high-quality look and feel, you will go for zinc.

Zinc die cast heat sink

Zinc die cast heat sink

Lastly, zinc heat sinks offer superb RFI and EMI shielding and performance.

Note: Both aluminum and zinc can be die cast to make complex-shaped heat sinks.

5.  Uses Of Die Cast Heat Sink

Die cast heat sinks are used in many industries for cooling various electronic components. They attain this by increasing the heat flow away from a hot device.

Generally, die cast heat sinks are used in any system that generates heat, be it mechanical, frictional, or electrical.

Below, we have highlighted some common uses of die cast heat sinks:

  • Audio hardware
  • Automotive hardware
  • Lasers with high power
  • Circuit/PC sheets
  • Communication gadgets
  • Lodgings, fixtures, and LED sheets

6.  Die Casting Custom Heat Sink

Customizing a heat sink aims to manufacture a heat sink that perfectly fits its intended application.

Below are the basic steps most we follow in die casting a heat sink:

I. You, as the client, will submit the specifications for the heat sink you require.

II. Our engineers will develop a CAD data and 3D models of the heat sink as per your specification.

III. After the data and the 3D models, we will seek your opinion, and necessary alterations will be made.

IV. We will then commence the production of the heat sink.

V. Finally, finishing is applied to the die cast heat sink. Common finishing includes chromatising, wet coating, and powder coating.

We also label and color-code the heat sinks on request as part of the customization.

custom heat sink

custom heat sink

Alternatively, we can modify standard heat sinks to suit your application.

7.  Parts Of Die Cast Heat Sink

Die cast heat sinks can be both simple and complex (modified). The parts will differ depending on the specific heat sink.

The standard components of a heat sink include:

  • Fins or Combs – To increase the surface area of contact with air.
  • Flat base – For holding the fins or combs protrusion.
  • Cooling method – This includes fans used in forced air convection.

Other parts that are integrated into modified heat sinks include:

  • Heat pipes
  • Heat spreaders
  • Vapour chambers

8.  Features Of Die Cast Heat Sink

A heat sink is integral in dissipating heat from electronic systems. The size of the heat sink will vary depending on the application.

The universal features of heat sinks include:

  • Material – The heat sink material usually has high thermal conductivity and is light. The common materials are aluminum and copper.
  • They have a flat base.
  • The presence of fin or comb protrusions increases the surface area of contact with air.
  • Cooling methods can be forced liquid or air convection, or natural air convection.
  • Application of thermal grease between the electronic device and the surface of te heat sink for good thermal contact.

9.  Die Cast Heat Sink Design

The heatsink design greatly influences the effectiveness of the heatsink. Consequently, the design stage is important.

Some key considerations when designing a heat sink include:

  • Thermal conductivity of the material of choice
  • The preferred attachment method for the heat sink.
  • Thermal resistance – Measured in 0C/W.
  • Arrangement, size, shape, and location of the heat sink fins
  • Thermal interface material
  • The mounting method is by screws, clips, glue, or sticky tape.
  • The surface area of the heat sink should be large for adequate heat dissipation.
  • The heat dissipation of the heat sink should equal the difference between the surrounding and the device temperature.
  • A fan can be incooperated in the heat sink design to make the heat sink cool twice as fast for better cooling performance.

Typically, the parameters of heat sinks are established through modeling and analysis of other heat sinks.

10.  Are There Modified Die Cast Heat Sink?

Modification of die cast heat sinks is aimed at making them more efficient. Some common modifications on heat sinks include:

Embedded Heat Pipes

Embedded heat pipes help to spread the heat over the entire heat sink.

Consequently, it lowers the temperature difference and increases the efficiency of the heat sink.

The modification is made by placing one end of the heat pipe on the system’s hotspot (the part prone to heating).

Embeded heat pipes

Embeded heat pipes

 The other end is installed in the cooler part of the heatsink, where it releases the heat.

Conclusively, the embedded pipes help in spreading the thermal load

Copper Heat Spreaders

As the name implies, copper heat spreaders aid in transferring heat from the hotter source (hotspot) to the cooler part (heat sink).

It more or less serves a similar function to embedded heat pipes.

Copper heat-spreaders are mainly used in CPUs, whereby the CPU is fixed inside the spreader, and the spreader is connected to the heat sink.

copper heat spreaders

copper heat spreaders

Vapor Chambers

Unlike heat pipes that transfer heat along their axis, vapor chambers transfer heat in two dimensions.

They also collect heat from a larger surface and transfer it to the heat sink. They are ideal for heat sinks in systems with high fluxes but small evaporation areas.

vapor chambers

vapor chambers

Note: Heat pipes and vapor chambers contain a fluid (mostly water) to influence the heat conductivity.

With continuous technological advancement, manufacturers are coming up with more modifications to make the heat sinks efficient.

11.  Die Cast Heat Sink Material

Before choosing a material for a die cast heat sink, you need to make the below considerations:

  • The thermal properties – This will affect the heat transmission through the heat sink’s fins.
  • Weight – The weight of the material will contribute to the final weight of the heat sink.

The main materials used for die cast heat sinks include aluminum, zinc, and copper.


Aluminum is a widely used material for diecast heat sinks because of the following properties.

  • Lightweight
  • Capability to resist high operating temperatures.
  • Superb heat dissipation (thermal conductivity) due to their strength and rigidity to corrosion
  • The main aluminum alloy used for die cast heat sink is the A356.


Arguably, zinc is the easiest material to die cast. Hence, it is also used to manufacture heat sinks. In addition, zin has the below properties:

  • Stronger and stiffer than aluminum.
  • Does not require plating. However, if need be, plating zinc is easy.
  • It provides the heat sink with a high-quality feel.
  • Has a lower tooling and unit cost than aluminum
  • Excellent shielding properties.


Copper is sometimes used to manufacture heat sinks due to its excellent thermal conductivity (about 400 W/m-K).

Since copper has a  temperature coefficient of expansion, it can be embedded into the die cast heat sink made of another material. As such, copper primarily offers a performance boost to a heat sink.

The primary copper alloy used in die cast heat sink is CDA110.

Notably, the primary reason why copper is rarely used as a material for the die cast heat sink is because of:

Also, it’s heavyweight (three times that of aluminum) and expensive.

12.  Surface Finish For Die Cast Heat Sink

The surface finishing will dictate how the heat sink will look after it is finished. As such, surface finishing entails adding material to the surface of the heat sink.

Surface finish can improve both the durability and attractiveness of the heat sink. The main surface finishing employed on die cast heat sinks include:

  • Powder coating
  • Chromating
  • Anodization

Importantly, the surface finishing greatly impacts the efficiency of the heat sink. Before choosing a surface finishing option, consult or do adequate research to ensure you make a proper decision.

13.  Die Casted Heat Sink Working Principle

As earlier mentioned, various systems produce heat due to several forces.

This heat needs to be removed to prevent accumulation which may damage the system.

The die cast heat sink plays the role of removing the heat through the below principle.

As the system runs, it gradually generates heat energy.

Depending on the configuration of the heat sink, the heat energy is directed towards the die cast heat sink actively or passively.

Alternatively, the heat may be transmitted to the heat sink through pipes.

Once in the heat sink, the heat is evenly spread through the fins.

Gradually, the heat is emitted into the much cooler surrounding. The cycle repeats itself provided the system is still operational.

14.  Increasing Efficiency Of Die Casted Heat Sink

Increasing the efficiency of the die casted heat sink greatly relies on the design of the heat sink. Below are some common alterations that can be incorporated in the design to make the heat sink efficient:

  • Increasing the number of fins – For better heat dissipation
  • Increasing the space between the fins – Increases the airflow
  • Adding inserts in the heat sink –To create continuity in the heat sink and increase heat absorption
  • Opting for active configuration – Generally, the active configuration of the heat sink is more efficient than the passive setup.

15.  Active Die Casted Heat Sink Vs Passive Die Casted Heat Sink

Active and passive configurations are the two main layouts for heat sinks. Basically, these configurations dictate how heat reaches and is transmitted by the heat sink.

Active Die Casted Heat Sink

Active die cast heat sinks use fans to blow the hot air from the heating component towards the heat sink’s fins.

In some scenarios, a case fan is employed to draw cold air from the outside; and blow the hot air from the inside components.

Active die casted heat sink

Active die casted heat sink

Arguably, the usage of fans by the active die casted heat sinks makes it more efficient in thermal regulation.

Passive Die Casted Heat Sink

The passive die cast heat sinks do not employ fans, unlike its active counterpart.

As the name implies, the heat sink allows heat to flow naturally towards it through convection.

Airflow is generated as the heat flows continuously towards the heat sink. This in turn, results to thermal regulation in the system.

passive die casted heat sink

passive die casted heat sink

Since no fans are employed, the passive die cast heat sink configuration is cheaper but less effective than the active configuration.

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