Industrial LED lighting
Integrate radial fins, mounting points and housing details around the LED thermal path.
CUSTOM THERMAL MANAGEMENT
Die Cast Heat Sinks
Integrate cooling fins, mounting features and structural details in one aluminum casting—engineered for your thermal load and repeat production.
Integrated geometry
Cooling and mounting in one part
Precision interfaces
CNC-finished contact surfaces
OEM production
From tooling review to repeat supply
Bring your thermal and mechanical requirements into one manufacturable design.
Discuss Your Die Cast Design
Cast-in cooling fins with draft angle and mirror-flat CNC machined contact pad
One Casting. A Complete Thermal Structure
Die casting forms aluminum into complex, repeatable shapes so your heat sink can also support the mechanical assembly.
Cast-in cooling fins
Shape the cooling surface around your available envelope and intended airflow.
Integrated mounting features
Combine bosses, ribs and attachment points to reduce separate brackets and assembly steps.
Finished where it matters
Machine critical contact faces and hole locations after casting for reliable fit and thermal contact.
Share the space, heat source and mounting constraints for your next assembly.
Review My Product RequirementsMake Every Cast Feature Work Harder
Use the freedom of a casting to solve cooling, mounting and handling needs together.
Fewer separate parts
Combine fins, ribs and fixing points in one body to simplify the bill of materials.
Geometry around the heat source
Place material and cooling area where the thermal path needs them.
Repeatable assembly
Use defined datums and locating features to make production fit more consistent.
Volume-ready economics
Amortize dedicated tooling across a stable product platform and annual demand.
Choose the Alloy Around the Job
Balance thermal conductivity, castability, strength and finishing requirements before the tool is committed.
| Alloy Route | Primary Application Focus | Engineering & Thermal Consideration |
|---|---|---|
| ADC12 | Complex cast geometry | Evaluate filling, strength and the thermal path together. |
| A380 | General structural castings | Review mechanical needs, processing and specified material data. |
| Specified high-conductivity aluminum | Thermally demanding designs | Select a qualified grade after casting trials and performance review. |
ADC12
Complex cast geometry
Evaluate filling, strength and the thermal path together.
A380
General structural castings
Review mechanical needs, processing and specified material data.
Specified high-conductivity aluminum
Thermally demanding designs
Select a qualified grade after casting trials and performance review.
Thermal conductivity is taken from the specified alloy and condition. ADC12 and A380 are separate material specifications; the final grade is stated on the approved drawing.
Design the Fins for Heat Flow and Die Release
Typical envelope: 50–400 × 50–400 × 10–120 mm (L × W × H); wall thickness: 2.5–6 mm. Review dimensions, alloy and fin geometry together for airflow, metal filling and reliable die release.
01
Draft and fin spacing
Set the taper, gap and height together so the casting can fill and eject reliably.
02
Consistent wall transitions
Use balanced sections and filleted roots to reduce abrupt changes in metal thickness.
03
Parting and ejection strategy
Place parting lines, gates and ejector marks away from critical interfaces.
04
Machining allowance
Reserve stock and accessible datums for the contact faces and precise installation features.
Catch tooling and thermal conflicts before they become expensive revisions.
Start a DFM ReviewA Thermal Design Built Around Your Operating Conditions
The useful result is the component temperature in your installation, with the heat source, interface and airflow defined.
01
Define the heat source
Provide continuous and peak losses, contact area, layout and the permitted component temperature.
02
Map the air path
Review inlet temperature, mounting orientation, obstructions and the installed fan operating point where applicable.
03
Validate the assembly
Confirm base temperatures with the selected TIM, fastening method and actual installation conditions.
Base-to-air thermal resistance = (base hotspot temperature − inlet air temperature) ÷ effective heat load. Device junction temperature also includes the package and interface temperature rise.
Send your heat load and temperature limits for a practical thermal review.
Discuss Thermal RequirementsPrecision Where the Casting Meets Your Device
Secondary CNC machining defines the interfaces that control contact, alignment and assembly consistency.
Contact-face flatness
Typical precision-finished target: ≤0.05 mm over 100 mm, reviewed against the drawing and clamping plan.
Thermal contact finish
Precision contact surfaces can be finished to Ra 0.8–1.6 μm where the design requires it.
Critical local dimensions
Selected local features can target ±0.02–0.05 mm within 100 mm after machining review.
Controlled masking
Keep coating away from specified contact, grounding, thread and sealing areas.
Mark your critical datums and contact faces so we can review them together.
Review My Critical InterfacesFinish for the Environment and the Interface
Choose corrosion protection and appearance while keeping the heat path, grounding and fit under control.
As-cast or cleaned
Retain a functional metal surface where the environment and appearance requirements allow.
Chemical conversion coating
Review corrosion protection and electrical contact requirements against the selected specification.
Powder coating
Specify coating thickness, color and mask boundaries so mating features remain usable.
Project-specific finish
Review alloy compatibility before specifying anodizing or another special finish for a silicon-rich casting.
Define the environment, appearance and masked surfaces before the first sample.
Plan My Surface SpecificationBuilt Into the Equipment You Design
Die cast heat sinks are useful where a cooling body also needs to carry structural or mounting functions.
Telecommunications equipment
Combine external cooling ribs with structural interfaces for compact outdoor electronics.
Industrial power electronics
Place mounting bosses and contact surfaces around the power devices and available airflow.
From Tooling Review to Repeatable Castings
One project team coordinates qualified casting partners, in-house precision machining and controlled inspection.
01
Requirements and DFM
Freeze the alloy, envelope, heat source, critical interfaces and expected annual volume.
02
Tooling preparation
Agree the parting strategy, draft, gates, ejection and machining allowances.
03
Trial casting
Review filling, casting integrity and dimensions before sample approval.
04
Secondary operations
Trim, deburr and machine approved contact faces, datums, holes and threads.
05
Finish and inspect
Apply specified finishes, verify masking and inspect drawing-defined characteristics.
06
Release and repeat
Link approved samples, records, labels and packaging to the controlled drawing revision.
Quality Evidence You Can Trace to the Part
Tie material, dimensions and functional checks to the approved drawing and production lot.
Material identification
Specified alloy, source records and batch traceability.
First article inspection
A dimensional report matched to the released drawing revision.
Casting integrity
Defined visual and integrity checks; additional CT or sectioning when the project calls for it.
Interface verification
Flatness, roughness, thread and critical feature checks as specified.
Thermal validation
Record the heat load, source area, inlet temperature, orientation and airflow.
Controlled release
Inspection records, part marking, packaging and engineering-change control.
Tell us the evidence your engineering and supplier-quality teams require.
Define My Inspection PlanCustomize the Features That Shape Your Assembly
Adapt the casting and its secondary operations to your thermal, mechanical and production requirements.
Envelope and fin layout
Match available space, heat-source position and the intended air path.
Bosses and locating features
Place mounting, alignment and support details where the assembly needs them.
CNC interfaces
Define contact pads, datums, hole positions and threads from the approved drawing.
Finish and masking
Specify color, coating thickness and surfaces that must remain uncoated.
TIM and mounting kit
Coordinate pads, fasteners and clamping requirements with the device interface.
Part marking and packaging
Align identification, barcodes and protective packing with your receiving process.
Turn your assembly requirements into one controlled casting specification.
Discuss OEM CustomizationPlan the Tooling, Volume and Delivery Together
A clear cost and timing breakdown helps procurement compare the complete production route.
500–1,000 pcs
Typical starting quantity for a new die cast tool; final economic batch depends on geometry and tooling.
4–8 weeks
Typical new tooling and first-article approval window after the required project inputs are confirmed.
12,000 pcs/year
Reference die cast heat sink capacity, allocated against part size, processing time and the agreed schedule.
| Commercial Scope Phase | Key Engineering & Supply Deliverables |
|---|---|
|
Tooling and development
|
Tool ownership, trial scope, revisions and approval milestones. |
|
Recurring part cost
|
Material, casting, machining, finish, inspection and packaging. |
|
Release schedule
|
Forecast, batch size, lead time and shipment plan after sample approval. |
Share your annual demand and target launch date for a scoped quotation.
Request a Project QuotationDie Cast Heat Sink Questions, Answered
Resolve the material, tooling and validation questions before moving to samples.
When is die casting a good fit for a heat sink?
It is a practical option when the part combines cooling fins with complex mounting or housing details and the expected volume can support dedicated tooling. The final choice also depends on thermal load and manufacturing constraints.
Can a die cast alloy replace extruded aluminum directly?
The specified alloy, geometry and thermal path need to be reviewed. Casting and wrought alloys have different properties, so matching the external size alone does not establish equivalent thermal performance.
Are the critical contact surfaces left as-cast?
Critical thermal contact faces, datums and selected holes can be CNC machined after casting. Required flatness, surface finish and tolerances are defined on the drawing.
Can you provide a universal power rating?
A useful rating needs the heat-source area, inlet temperature, airflow or natural-convection orientation, interface material and temperature limit. We assess the part under the agreed operating conditions.
What information is needed for a quotation?
Send a STEP model and dimensioned drawing if available, the heat load and contact area, mounting envelope, target temperatures, finish, annual demand and target launch date.
How are tooling and production changes controlled?
The approved drawing, material specification, tooling scope and inspection plan define the baseline. Relevant changes are reviewed and approved before they enter repeat production.
Have a drawing-specific question? Bring it to the engineering review.
Ask a Die Casting Question
Bring Your Die Cast Heat Sink Project to Life
Share the heat load, geometry and production goal. Our team will review the fit and outline a practical next step.
Thermal and DFM review
Connect the heat path with a feasible casting geometry.
Qualified material routes
Select the alloy and finishing specification for your job.
Critical interface machining
Define the contact faces and assembly datums.
Sample-to-production coordination
Keep drawing revisions and approval records aligned.
One accountable project contact
Coordinate engineering, quality and delivery.