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- Extrusion Typical Fin Thickness (Ft) – 0.8 to 0.5mm with a typical Gap Width (Gw) of 5mm to 1.5mm
- Pro – inexpensive tooling and inexpensive parts
- Con – limited on fin thickness and prefers relatively high volume
- Volume – typically need 500kg of material per order (number of parts x Kg per part greater than or equal to 500kg).
- Material – copper or aluminum
- Skiving – Ft = 0.6mm to 0.2mm and a Gw = 3.0m to 1.0mm
- Pro – Low volume with relatively low cost, Low tooling cost and thin fins (copper or aluminum).
- Con – parts can be more expensive and cosmetics are not great – fins are typically curved.
- Volume – typically low
- Material – copper or aluminum
- Cold Forging – Ft = 0.8mm to 0.5mm and a Gw = 8mm to 1.0mm
- Pros – various types of fins such as pin fins, elliptical fins and or straight with cross cuts.
- Cons – tooling can be expensive.
- Volume – typically low volumes - - less than 10k/month.
- Material – copper of aluminum
- Snapped Fins – Ft = 0.5mm to .15mm and a Gw = 2mm to 0.8mm
- Pros – thin fins, can have CU base and AL fins, low cost for high performance heat sinks.
- Cons – expensive tooling. Tooling is in the $4k (per fin) range. May need multiple fin tools per heatsink.
- Volume – High volume 2k to 200k per month
- Material – copper or aluminum
- Stamping – Typically for high volume low wattage devices.
- Pros – very inexpensive
- Cons – two dimensional and for very low wattage. Tooling is in the $4k to $10k range depending on number of cavities needed to support the volume.
- Volume – High volume 25k to 250k/month
- Tower heat sinks
- Pros – for high wattage applications with a relatively low weight
- Cons – tooling can be expensive and part cost is relatively high
- Volume – from 100/mnt to 100k/mnt
- Material – copper or aluminum
- Typically for high performance applications
Notation for Heatsinks: - W = width of the heatsink - this is perpendicular to the airflow
- L = length of the heatsink - parallel with the airflow and also the length of the fins
- Ho = height overall - includes the fin height and the base thickness
- Fh = fin height
- Ft = fin thickness (or fin diameter for pin fin heatsinks)
- Gw = gap width - space between the fins (this is NOT the fin pitch)
- Fp = fin pitch - measured from center of fin to center of next fin
- Bt = base thickness
- M = material - Copper or Aluminum
Click on the images below for examples:
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