Custom Extruded Heat Sinks — Designed and Built for Production
We manufacture custom aluminum extruded heat sinks and assemblies, from thermal design and prototyping to mass production. Send your drawing and requirements—we’ll engineer a manufacturable, repeatable cooling solution built for your production plan.
RFQ in 3 steps
From first drawing to production-ready quote — streamlined for engineering and procurement teams.
Send your files
Email your 2D/3D files and requirements: drawing, STEP/IGES, heat load, max device temperature, ambient, airflow, envelope, annual volume.
DFM review
We review for DFM, select the optimal process, and propose cost/lead time with risk notes and alternatives if needed.
Approve & ramp
Approve quote → prototype → validation → pilot run → mass production.
Preferred formats: AutoCAD, SolidWorks, Creo. We also accept PDFs with critical dimensions.
What we build
- ✓Custom aluminum extruded heat sinks in 6061 and 6063
- ✓Integrated machining: milled pockets, drilled/tapped holes, cut-to-length, cross-cut, deburr
- ✓Surface finishing: anodizing, hard anodizing, nickel plating, passivation, sandblasting, polish and clean
- ✓Friction stir welded (FSW) assemblies for ultra-wide heat sinks
- ✓Hybrid modules: extrusion plus heat pipes, bonded or zipper fins, or skived sections where higher fin density is required
- ✓Build-to-print components and full custom thermal assemblies
Extruded heat sink capabilities
| Parameter | Capability |
|---|---|
| Materials | Aluminum 6061, 6063 |
| Extrusion press range | Approximately 800–5,000 tons for demanding profiles |
| High-performance profiles | Fin aspect ratios above 20:1 depending on geometry |
| Ultra-wide designs | Multi-extrusion integration via FSW; assemblies up to approximately 762 mm (30 in) width depending on design |
| Secondary operations | CNC milling, drilling, tapping, cross cutting, cut-to-length, deburring, cleaning, anodizing |
| Integration | Heat pipe embedding, soldering/brazing for mixed-material assemblies, nickel plating as required |
If extrusion alone can’t meet your thermal target or geometry, we’ll combine processes. Our in-house skiving, cold forging, bonded fin, soldering/brazing, and FSW options let us balance thermal performance, pressure drop, weight, cost, and volume.
Engineering before manufacturing
A high-performing extruded heat sink demands more than a good die. We evaluate:
- ✓Heat load, heat source size and placement
- ✓Airflow rates and pressure drop targets
- ✓Fin geometry and spacing for convective performance
- ✓Base thickness for spreading and flatness
- ✓Mounting and interface (TIM, fasteners)
- ✓Surface treatments and corrosion environment
- ✓Production volume, cost targets, and supply chain risk
Our support includes
- •Thermal solution development
- •Mechanical design
- •DFM and manufacturability review
- •Material and process selection
- •Thermal simulation support
- •Prototypes
- •Product optimization
- •Thermal resistance testing
Why HeatsinkMaker
Engineering-driven, multi-process manufacturing with validated paths from prototype to volume production.
Multi-process manufacturing
Extrusion, skiving, cold forging, bonded fin, soldering, brazing, FSW, and CNC under one roof.
Engineering-driven
We align thermal targets with manufacturable geometries for repeatable results.
Prototype-to-volume
Validated path from samples to stable mass production with quality gates.
Precision machining
CNC capability with machine precision down to ±0.002–±0.008 mm on machined features.
Quality inspection
Dimensional checks, CMM, 2D measurement, and thermal testing.
Reliable capacity
Stable output for aluminum, skived, liquid cold plate, and soldered Al/Cu heat sinks.
Design options and alternatives
When single extrusions reach their limits, we combine processes to meet thermal, mechanical, and cost constraints.
FSW extruded assemblies
For width and fin aspect ratios beyond single-extrusion limits. We routinely target fin aspect ratios >40:1 on FSW assemblies, subject to geometry.
Hybrid extrusion + skiving
Extruded base for structure; skived fins where higher fin density is needed in critical zones.
Extrusion with heat pipes
Spread concentrated heat to a broader fin field without oversizing the base.
When extrusion isn’t suitable
We’ll propose skived, cold forged, bonded fin, or brazed solutions to meet thermal and mechanical constraints.
Quality, testing and inspection
- ✓Dimensional inspection and CMM
- ✓Surface inspection and finish verification
- ✓Thermal resistance testing (air-cooled modules)
- ✓Assembly fit and torque checks
- ✓For hybrid assemblies: solder/braze integrity checks
- ✓For liquid-cooled add-ons: leakage and pressure testing when applicable
Verification standards
Our inspection plans align with production volumes and critical-to-quality dimensions. We document results and provide inspection reports with shipments when specified.
Industries we serve
How we work with your team
1. Buyer and engineering alignment
We maintain clear manufacturability feedback and cost drivers so procurement and design share the same constraints.
2. Risk notes up front
We flag die complexity, downstream machining risk, and finishing risks early with mitigation options.
3. Cost/lead time drivers
We quantify die complexity, profile mass and width, secondary machining content, anodizing class and color, and packaging.
4. Documentation
PPAP or equivalent build documentation available upon request; inspection reports for critical dimensions included with shipments when specified.
What to include in your RFQ
- ✓2D drawing and 3D model (if available)
- ✓Heat load and allowable maximum device temperature
- ✓Ambient temperature and airflow details (forced/natural, CFM, pressure drop constraints)
- ✓Envelope/space, mounting scheme, weight limits
- ✓Surface finish/anodizing requirements
- ✓Expected annual volume and release cadence
- ✓Target cost or cost priorities, sample quantity, desired pilot/mass production timing
File formats
Send files in AutoCAD, SolidWorks or Creo formats, or as STEP/IGES with a dimensioned PDF.
From prototype to production
Prototype
Function-first samples for thermal validation.
Validation
Test and refine fin geometry, base thickness, and surface finish.
Pilot run
Confirm repeatability, quality plan, and packaging.
Mass production
Stable schedule with agreed inspection and logistics.
HeatsinkMaker is your extruded heat sink manufacturing partner—from thermal concept to dependable, repeatable production.
Ready to quote?
Email your RFQ with drawings and requirements. We’ll review, recommend the best manufacturing route, and provide a clear plan for prototyping and production.