Bonded Fin Heat Sinks

Large-format cooling. Engineered around your airflow.

Custom aluminum and copper fin assemblies for industrial drives, inverters and energy storage power conversion. Turn your thermal limits into a manufacturable, repeatable design.

Custom geometry

Base, fin height and spacing built around your enclosure

Controlled bonding

Defined bond lines and validated fin retention

Production continuity

From engineering samples to scheduled batch supply

Bring us your thermal challenge. We will help define the next step.

Discuss Your Bonded Fin Design

Individual aluminum plate fins bonded into a machined base with mounting margins

Machined Groove Base

Individual Fins

Controlled Thermal Joint

What Is a Bonded Fin Heat Sink?

Separate fins. A machined base. More freedom to fit your thermal design.

Individual aluminum or copper fins are inserted into a grooved base and joined with a controlled thermally conductive adhesive. This construction allows a larger cooling surface and more flexible fin geometry than a single extruded profile.

Machined base

Spreads heat from the device mounting surface into the fin field.

Individual fins

Height, thickness and spacing can be tuned to the available airflow.

Controlled thermal joint

Bond-line thickness, surface preparation and cure conditions work together to support repeatable heat transfer.

Find out whether bonded fins suit your mechanical envelope.

Review Your Cooling Envelope

More Design Freedom Where It Matters

Build the fin field around the system instead of forcing the system around a fixed profile.

Larger cooling footprints

Create broad fin arrays for distributed power modules without relying on one extrusion cross-section.

A better airflow match

Adjust fin height and channel spacing to balance heat transfer, air pressure drop and fan capability.

Material flexibility

Combine base and fin materials to balance heat spreading, weight and project cost.

Installation-ready geometry

Machine mounting holes, clearances and contact surfaces into a controlled assembly design.

Turn your space, airflow and cost constraints into a practical design.

Explore Your Design Options

A Manufacturing Envelope for Larger Loads

Start with a clear mechanical scope, then refine the details against your application.

Envelope Capacity

600 × 900 mm

Maximum configurable assembly footprint

Integrated Thermal Assessment

Dimensions, fin geometry and mass are reviewed together with handling strength, bonding access and the device mounting pattern.

Overall dimensions	100–600 × 100–900 × 30–180 mm
Fin thickness	0.5–1.5 mm
Maximum single-piece mass	35 kg
Base and fin materials	Aluminum or copper
Local contact-face flatness	Typically ≤0.05 mm over 100 mm
Machined contact finish	Ra 0.8–1.6 μm where specified

Final dimensions, tolerances and inspection datums are defined on the approved drawing.

Share your drawing for a geometry and tolerance review.

Check Manufacturing Feasibility

The Bond Line Is Part of the Thermal Design

A reliable fin joint needs controlled preparation, assembly and validation.

Thermally conductive adhesive connects each fin to the base. We define the joint around the selected materials, service temperature and mechanical loads, then verify the process on representative samples.

Prepare the surfaces

Control groove geometry, cleanliness and mating surfaces before dispensing.

Control the assembly

Define adhesive placement, fin insertion, fixture alignment and cure conditions.

Validate the connection

Evaluate bond-line consistency, fin pull strength and temperature cycling against the agreed acceptance plan.

Physical cut section of plate fins bonded into blind grooves in an aluminum base

1. Straight Individual Fin

2. Precision Machined Groove

3. Controlled Adhesive Bond-Line

4. Base Plate Heat Spreader

Build confidence in the joint before releasing the assembly.

Discuss Bond Validation

Choose Materials for the Whole Assembly

Balance conductivity, weight, corrosion resistance and the condition of every joining surface.

Aluminum base and fins

A practical starting point for large cooling surfaces where weight and system cost matter.

Copper where spreading matters

Consider copper at concentrated heat sources or in the fin field when the thermal benefit justifies added mass.

Surface protection

Specify natural finish, anodizing, conversion coating or nickel plating around material and service requirements.

Keep interfaces controlled

Define masking at thermal contact areas, grounding faces, threads and bond surfaces on the drawing.

Select the material and finish combination that fits your operating environment.

Review Materials and Finishes

Design for the Air That Actually Reaches the Fins

Fin density only helps when the fan and duct can deliver the required flow through the assembly.

We assess the installed fan operating point, bypass paths and pressure drop through the fin channels. Spacing is selected for the enclosure, inlet conditions and maintenance needs.

Channel Flow & Static Head Analysis CFD / Airway Schema

Evaluating parallel fin channels against system resistance and bypass clearance.

Inlet Airflow Vector (Installed Static Head)

▼▼▼▼▼▼▼▼▼

Grooved Base Plate & Bonded Adhesive Root

Effective Channel Velocity

Individual Fins (0.5–1.5mm)

Precision Base Plane

Define the heat source

Record heat load, source area, mounting pattern and the permitted base temperature.

Use installed airflow

Measure the flow through the effective fin cross-section and record inlet air temperature and air pressure drop.

Compare like-for-like

Use the same heat source, interface, measurement locations and installation conditions when comparing designs.

Thermal Resistance Formula:

Rθ = (base hotspot temperature − inlet air temperature) / effective heat load

Send your fan curve and operating limits for an airflow review.

Plan Your Thermal Evaluation

Built Around Industrial Power Applications

Match a large fin surface to the heat sources, air path and service conditions of the equipment.

Industrial drive cabinet with supported vertical fin cooling assembly

Industrial drives

Distribute IGBT or SiC module heat across a shared base while coordinating fin channels with the cabinet airflow.

Energy storage power conversion cabinet with large vertical fin heat sink

Energy storage PCS

Plan for converter duty cycles, elevated inlet temperatures and repeatable mounting across power modules.

Industrial inverter chassis with vertical fins and open lower air intake plenum

Industrial inverters

Integrate a large fin array with the enclosure, fan arrangement and access needed for assembly and maintenance.

Let us review the cooling requirements of your equipment.

Discuss Your Application

Assembly technician positioning a full-length aluminum fin in a dedicated bonded-fin alignment fixture

Controlled Adhesive Dispensing & Precision Fixture Alignment

A Controlled Route from Base to Fin Assembly

Keep geometry, bonding and final interfaces connected through one manufacturing plan.

Machine the base

Create the grooves, datums and device interfaces from the released drawing.

Prepare the fin set

Inspect material, straightness and fin dimensions before surface preparation.

Bond and cure

Meter the adhesive, locate the fins in dedicated fixtures and apply the defined cure cycle.

Finish and inspect

Verify the final contact surface, mounting features, fin alignment and release documentation.

Align the drawing and process before your first sample build.

Start a DFM Review

Verification You Can Carry into Production

Translate the approved sample into measurable controls for repeat orders.

CMM & Optical Metrology Inspection Laboratory

Critical dimensions

Inspect mounting datums, hole patterns, contact-face flatness and fin alignment.

Connection integrity

Check fin retention and bond consistency using the agreed process and sample plan.

Thermal performance

Record load, inlet temperature, installed airflow and measurement positions with the test result.

Batch traceability

Link material lots, work orders, process records and inspection results; retain traceability records for five years.

5 Years Archived Traceability

Comprehensive retention of raw material certificates, heat treat logs, adhesive batch numbers, and CMM dimension verification reports.

Define the inspection and reliability evidence your team needs.

Build Your Inspection Plan

Engineering Documents That Keep Teams Aligned

Give engineering, sourcing and quality a shared technical basis for approval.

Design package

2D drawings and STEP models
Material and surface specifications
DFM recommendations and interface details

Validation package

Thermal test conditions and results
Bond-strength and temperature-cycle scope
First-article and critical-dimension reports

Production package

Material certificates and CoC
Agreed control plan and batch records
Packaging specifications and engineering change history

Tell us which documents your approval process requires.

Define Your Document Package

A Clear Path from Sample to Repeat Supply

Move forward with defined inputs, approval gates and an agreed production schedule.

Requirements review

Share the drawing or thermal boundary conditions, expected quantity and project timing.

DFM and quotation

Review geometry, bonding requirements, inspection scope and cost drivers.

Sample approval

Validate the first article, thermal behavior and installation before freezing the design.

Batch release

Build to the approved revision and coordinate repeat deliveries with your forecast.

Engineering samples

From 1 piece

Large bonded-fin batches

Typically 10–20 pieces

Drawing-based samples

Typically 10–20 working days after drawing freeze

Map the sample and approval schedule for your project.

Plan Your Sample Build

Get a Quote Your Team Can Compare

A complete technical brief helps us price the assembly, tooling and validation on the same basis.

Technical Brief Checklist

Geometry and interfaces: Send the 2D drawing, 3D model, mounting pattern and allowable envelope.

Thermal boundaries: Include heat load, source footprint, inlet air temperature, fan curve and target temperatures.

Production requirements: Confirm materials, finish, expected quantities, inspection needs and delivery timing.

Transparent Cost Scope

Transparent cost scope: Separate material, machining, bonding fixtures, finishing, testing and protective packaging in the quotation.

Itemized tooling & fixture costs: Dedicated assembly tooling, bonding nests, and CMM inspection programs separated from recurring part production.

Batch volume thresholds: Tiered pricing breakdown for 1-piece sample builds, pilot pre-series (10–20 pcs), and high-volume scheduled batch releases.

We can review fin spacing, material allocation, mounting features and inspection scope together to reduce avoidable manufacturing and assembly cost.

Prepare one clear brief for engineering and commercial review.

Request a Project Quotation

Bonded Fin Heat Sinks: Common Questions

Practical answers before you share a drawing or start a sample build.

When should I consider bonded fins?

Consider bonded fins when a large footprint, tall fins or geometry outside a convenient extrusion profile is needed. The choice depends on airflow, mass, joint requirements and manufacturing cost.

Is the fin joint soldered or brazed?

For this product family, Morton uses a controlled thermally conductive adhesive. The adhesive and joining process are selected and validated for the approved service conditions.

Can aluminum and copper be combined?

Yes. We assess thermal expansion, joint design, environmental exposure, surface treatment and weight before approving a mixed-material assembly.

Can you quote a fixed cooling wattage?

The thermal rating depends on the heat-source area, inlet temperature, actual airflow, interface and installation. Share these conditions so the evaluation represents your equipment.

What is needed for an engineering sample?

A drawing or thermal brief, mounting constraints, material and finish preferences, and the intended test conditions. Charged engineering samples can start from one piece.

How are the fins protected in transit?

Packaging is defined around fin stiffness, assembly mass and handling routes. We use separation, restraint and protective support to reduce fin deformation and contact-face damage.

Resolve the remaining technical questions with our engineering team.

Ask a Bonded Fin Question

Let’s Engineer Your Bonded Fin Solution

Share your drawing or operating conditions. Morton will help turn the requirements into a practical sample and production plan.

Application-led thermal design

Geometry and airflow reviewed around your equipment.

Controlled fin bonding

Defined preparation, assembly and validation requirements.

Samples from one piece

Start with a focused engineering build.

Traceable repeat supply

Approved drawings and documented production controls.

One coordinated project team

Engineering, quality and sourcing aligned from the start.

Tell Us About Your Project

A drawing is helpful. A clear thermal brief is a good starting point too.