COFAN THERMAL

Extruded Heatsink

An extruded heatsink is a type of thermal management device designed to dissipate heat from electronic components, ensuring they operate within safe temperature limits. The process of creating an extruded heatsink involves the extrusion of a metal, typically aluminum, through a die to form a continuous profile with fins or other features that enhance its ability to dissipate heat.
Extruded heatsinks are favored for their relatively low cost and high efficiency in thermal management. The extrusion process allows for the production of heatsinks in various shapes and sizes, tailored to specific applications and performance requirements. Additionally, the durability and lightweight properties of aluminum make these heatsinks suitable for a wide range of environments and conditions.

Extrusion Heatsink (Rectangle)

Extruded Heatsink (Rectangle)

Extrusion Heatsink (Circle)

Extruded Heatsink (Circle)

- HEAT SINK

Type: Extrusion Heat Sink
Brand Name: Cofan Thermal
Place of Origin: Dongguan, China
Application: LED Lighting Fixture
Delivery Time: 4 Weeks L/T

- Product Information -

Place of Origin:
Dongguan, China
OEM:
Yes
Process:
Extrusion
Brand Name:
Cofan Thermal
Material:
Aluminum 6063
Shape:
As Shown in the Picture
Application:
Lighting Fixture
Size:
84 x 69mm
Finish:
Clear Anodizing
Delivery TIme:
4 Weeks L/T

- HEAT SINK

Type: Extrusion Heat Sink
Brand Name: Cofan Thermal
Place of Origin: Dongguan, China
Application: Type here
Delivery Time: 4 Weeks L/T

- Product Information -

Place of Origin:
China
OEM:
Yes
Process:
Extrusion
Brand Name:
Cofan Thermal
Material:
Aluminum 6063
Shape:
As Shown in the Picture
Application:
Lighting Fixture
Size:
135 x 102 x 56mm
Finish:
Clear Anodizing
Delivery TIme:
4 Weeks L/T

- HEAT SINK

Type: Extrusion Heat Sink
Brand Name: Cofan Thermal
Place of Origin: Dongguan, China
Application: Thermal Management
Delivery Time: 4 Weeks L/T

- Product Information -

Place of Origin:
China
OEM:
Yes
Process:
Extrusion, CNC
Brand Name:
Cofan Thermal
Material:
Aluminum 6061
Shape:
As Shown in the Picture
Application:
Lighting Fixture
Size:
46 x 40 x 7mm
Finish:
Clear Anodizing
Delivery TIme:
4 Weeks L/T

- HEAT SINK

Type: Extrusion Heat Sink
Brand Name: Cofan Thermal
Place of Origin: Dongguan, China
Application: Thermal Management
Delivery Time: 4 Weeks L/T

- Product Information -

Place of Origin:
Dongguan, China
OEM:
Yes
Process:
Extrusion, CNC
Brand Name:
Cofan Thermal
Material:
Aluminium 6061
Shape:
As Shown in the Picture
Application:
Lighting Fixture
Size:
49 x 36 x 24mm
Finish:
Black Anodizing Finish
Delivery TIme:
4 Weeks L/T

- HEAT SINK

Type: Extrusion Heat Sink
Brand Name: Cofan Thermal
Place of Origin: Dongguan, China
Application: Type here
Delivery Time: 4 Weeks L/T

- Product Information -

Place of Origin:
Dongguan, China
OEM:
Yes
Process:
Extrusion, CNC
Brand Name:
Cofan Thermal
Material:
Aluminium 6061
Shape:
As Shown in the Picture
Application:
Lighting Fixture
Size:
50 x 50 x 44mm
Finish:
Black Anodizing Finish
Delivery TIme:
4 Weeks L/T

- HEAT SINK

Type: Wave Fin Extrusion
Brand Name: Cofan Thermal
Place of Origin: Dongguan, China
Application: Thermal Management
Delivery Time: 4 Weeks L/T

- Product Information -

Place of Origin:
China
OEM:
Yes
Process:
Extrusion
Brand Name:
Cofan Thermal
Material:
Aluminum 6063
Shape:
As Drawing
Application:
Thermal Management
Size:
As Drawing
Finish:
Clear Anodizing
Delivery TIme:
4 Weeks L/T

- HEAT SINK

Type: Extrusion
Brand Name: Cofan Thermal
Place of Origin: Dongguan, China
Application: Thermal Management
Delivery Time: 4 Weeks L/T

- Product Information -

Place of Origin:
China
OEM:
Yes
Process:
Extrusion
Brand Name:
Cofan Thermal
Material:
Aluminum 6063
Shape:
As Drawing
Application:
Thermal Management
Size:
As Drawing
Finish:
Clear Anodizing
Delivery TIme:
4 Weeks L/T

Cofan’s Extruded Aluminum Heatsinks is a primary thermal management manufacturing method used to produce heatsinks for a wide range of applications covering low, mid, and high-volume applications.  Extruded aluminum heatsinks combine cost-effectiveness, design flexibility, good thermal performance, and ease of post-extrusion secondary machining operations.  These advantages make them a preferred solution for thermal management across multiple industries, ensuring efficient and reliable heat dissipation in a wide range of applications.  These applications include the following:

Consumer Electronics: Extruded Heatsinks are used in devices such as computers, laptops, smartphones, and gaming consoles to manage the heat generated by processors and other electronic components. Additionally, because they can be finished to consumer-grade cosmetics, audio amplifiers use many heatsinks to cool the many drivers embedded within the unit.

Power Electronics: Inverters, power supplies, and voltage regulators use extruded aluminum heatsinks to dissipate heat and maintain optimal operating temperatures.

Network Equipment: Electronic components in Routers, switches, and servers require efficient thermal management to ensure reliable operation and prevent overheating and extruded heatsinks can effectively remove the heat from the components to the surrounding ambient environment.

Cell Towers: Extruded Aluminum heatsinks are used in base stations and other telecommunications infrastructure to dissipate heat generated by high-power radio frequency (RF) components.

Electric and Hybrid Vehicles: Extruded Heatsinks are used extensively within the electric and hybrid vehicle ecosystem and are essential for cooling power electronics, battery packs, and motor controllers.

Avionics: Heatsinks are used extensively throughout the avionics systems to manage heat generated by the various electronic components and sub-systems in aircraft. This includes displays, on-board entertainment systems and guidance systems.

Satellites: Thermal management of electronic systems in satellites and spacecraft is especially critical and extruded heatsinks offer reliable conductive cooling solutions.

Solar Inverters: Extruded Aluminum heatsinks help dissipate heat from power inverters and cool concentrated photovoltaic systems thereby improving the efficiency used in solar power generating systems.

Wind Turbines: Heatsinks are used in the electronic control systems of wind turbines to ensure efficient thermal management.

Machinery: Industrial machines and equipment, such as CNC machines and automation systems, use extruded heatsinks to cool motors, drives, and control units.

LED Lighting: High-power industrial LED lighting systems require effective heat dissipation to maintain performance and longevity.

Imaging Equipment: MRI machines, CT scanners, and other medical imaging devices use extruded heatsinks to cool their electronic systems.

Diagnostic Instruments: Heatsinks are used in various diagnostic equipment to manage the heat generated by electronic components.

Radar & RF Systems: Extruded Aluminum heatsinks are used in radar and communication systems to dissipate heat from high-power electronic components. The use of Lightweight aluminum heatsinks is particularly advantageous for airborne systems

Electronic Warfare: Thermal management is critical in electronic warfare systems to ensure reliability and performance.

Servers: Data centers use extruded heatsinks to manage the heat generated by servers and other networking equipment.

High-Performance Computing: Supercomputers and high-performance computing systems rely on heatsinks for effective thermal management.

Extruded Aluminum Heatsinks manufactured by Cofan are produced using a method known as the extrusion process. This extrusion process is a manufacturing technique used to create objects (specifically heatsinks) with a fixed cross-sectional profile by forcing an aluminum alloy through a shaped die. Creating the heatsink or object is accomplished by pushing or drawing a heated aluminum billet through the shaped die profile into an extrusion press where a hydraulic ram forces it through a steel die. This steel die profile is specifically designed to create the desired cross-sectional shape and features of the heatsink (see Figure 5). The die profile can be made to produce complex fin structures and integrate other features necessary for effective heat dissipation. Depending on the complexity of the final shape and integrated features of the heatsink, the die profile classification falls into one of three basic categories: Solid, semi-hollow, and hollow. The majority of heatsink extrusion die profiles, due to the incorporation of cooling fins into their design, are classified as semi-hollow. Hollow die profiles create heatsinks with wholly encased features such as liquid cooling channels into the heatsink base or produce water and dust resistance enclosure or chassis. Solid dies are the least expensive while hollow dies are the most expensive to produce.

The size of extrusion presses used to make extruded heatsinks varies depending on the dimensions and complexity of the heatsink profiles being produced. Extrusion presses are characterized by their tonnage and circle size, which indicates the amount of force they can apply to extrude the material through the die. The circle size of the press determines the maximum width and height limits of the extruded profile. Any profile that can fit within the circle of a given diameter can be extruded by that press. Different extrusion presses have different circle sizes, and this capacity defines what size profiles can be manufactured on that press. Larger circle sizes allow for the production of bigger profiles. Shown below are some general guidelines on the sizes of extrusion presses typically used by Cofan for manufacturing heatsinks:

Small to Medium Extrusion Presses (500 to 1,500 tons)

Profile Size: Suitable for small to medium-sized heatsink profiles.

Applications: Commonly used for electronic components such as CPUs, GPUs, and small power transistors.

Capabilities: Can handle profiles with moderate complexity and dimensions, typically with fin heights and spacing that fall within common design parameters for heatsinks.

Medium to Large Extrusion Presses (1,500 to 3,500 tons)

Profile Size: Suitable for larger and more complex heatsink profiles.
Applications: These presses are commonly used for medium-sized heatsinks found in desktop computers, LED lighting, and moderate power electronics. and general applications requiring significant heat dissipation.
Capabilities: Can produce profiles with higher aspect ratios and more intricate fin designs, as well as larger cross-sectional areas.

Large Extrusion Presses (3,500 tons and above)

Profile Size: Suitable for very large heatsink profiles and those requiring extensive width (Up to 22”) and length.
Applications: Used for heavy-duty industrial applications, large-scale electronic systems, and specialized automotive components.
Capabilities: Capable of producing very large and complex profiles, including those with significant fin height and complex geometries.

The method of manufacturing extruded aluminum heatsinks allows for several advantages:

Versatility in Design and Options: The extrusion process allows for a wide range of cross-sectional heatsink profiles to meet specific thermal and mechanical requirements for relatively low tooling and production minimum charges (when compared to other heatsink manufacturing technologies). This single type of manufacturing process can produce a range of products from those that are fully enclosed (e.g. enclosures with internal or external cooling fins, integrated, liquid cooling tubes) to those with cooling fin features open to the ambient environment (See Figure 5).

Custom Shapes and Sizes: The extrusion process can create intricate fin structures and other features that enhance thermal performance and reduce post-extrusion secondary machining costs. Design Engineers can create custom shapes and sizes to fit specific applications, accommodating various thermal and spatial requirements. The process lends itself to a wide range of form factors. Within some design and manufacturing limitations, overall heatsink widths can be extruded as small as 1/8” up to 22”, and heights up to 9” tall. The flow length of extruded heatsinks is only limited by the extrusion press and handling capabilities. While long extrusions are possible, practically, they must be cut to manageable sizes for further processing and application. Design engineers also have additional control over the fin height, width, and thickness. See Figure 5.

High Aspect Ratio. Aspect ratios up to 14:1 or even higher, depending on the specific design and application requirements can be produced using extrusion presses with the higher tonnage rating. The general rule is that as the extrusion circle size increases (and tonnage), the achievable aspect ratio also increases. This is because larger profiles can support more complex and taller fin structures, whereas smaller profiles are typically lower because the fins need to be thicker to maintain strength during the production process.

Material: Cofan uses 6063 aluminum alloy for the majority of the extruded heatsinks it designs and manufactures. This aluminum alloy has excellent thermal conductivity properties while maintaining the desired physical properties of high strength, excellent post-extrusion machinability and finishing. Other aluminum alloys, such as 1060, 6101, and 6061, are also available depending on the application; however, the use of these alloys have specific tradeoffs either in machinability, thermal conductivity, or ability to integrate specialized features.

Ease of Machining and Assembly & Labor Savings Features: Extruded heatsinks can have a wide variety of post-extrusion and assembly labor-saving features extruded directly into the heatsinks. These include
– Integrating/Incorporating a “screw boss” into the design to save the cost of drilling a hole. And using a thread-forming / self-tapping screw during assembly.
– Incorporate PC Board Slots or Serrated extruded slots for threaded hardware into the extrusion design.

Aesthetic Appeal: Extruded heatsinks can be finished by anodized or coated in various colors, improving their appearance and providing additional customization options for visible applications.

Variable heatsink Fin Density and Thickness: The spacing or fin density and orientation of fins can be designed or tailored to maximize airflow and minimize pressure drop resistance, improving the efficiency of both natural and forced convection cooling regimes. The heatsink fin thickness is another variable that can be controlled to optimize thermal performance.

Enhanced Thermal Management Options: Extruded heatsinks can be easily integrated with fans or blowers to create active cooling solutions, enhancing their thermal management capabilities. They can be further combined with heat pipes or vapor chambers to distribute heat more effectively across the heatsink again improving the thermal performance of the system.

Quick Turn Prototyping: Extruded heatsinks can be prototyped without hard tooling by either of two methods. The first is to machining from 6063 aluminum alloy plate stock. The second is Cofan’s Skiving Process.

With over 30 years of designing and manufacturing extruded heatsinks, Cofan has built over 10,000 extrusion dies. This gives Cofan a significant design for manufacturing advantage (DFM) experience. Over this time, Cofan has developed the internal capability to produce heatsinks from the simple to the more complex allowing for thermal performance challenges to be realized. Each of these categories offers efficiencies based on the application, power levels, and physical space available. These configurations provide for optimized space utilization.
Shown below are the primary design configurations of heatsink Extrusions

Cofan Heatsink Extrusion Services

Cofan supports our customers’ needs for extruded heatsinks in numerous ways. The primary reasons customers turn to Cofan are for assistance with product design and fabrication requirements

Cofan New Product Design Assistance: Our experienced staff of application engineers, can help you in designing the most cost-effective solution for your application. We can design a new shape that will meet the thermal requirements of your application. If required, our staff can run Computational Thermal Dynamic (CFD) models to optimize the performance of the heatsink and validation the predicted performance of the heatsink in the intended application.

Cofan Fabrication Options: Cofan has several different options for supplying Extruded Heatsinks.

  Supplying Full or Cut-to-Length Raw Material Extrusion Lengths: This option allows our customers to take advantage of their in-house machining capabilities. Cofan can provide material in the following configurations:
• Raw extrusion sold by the length in bar form (typically 1.5 meters lengths)
• Extrusion cut to precision length and cut

Complete “Build to Print” Fabrication Assemblies: This option enables our customers to minimize their supply chain footprint by having Cofan handle the entire fabrication process. Cofan’s manufacturing facilities, located worldwide, offer comprehensive machining and finishing services, including:
• CNC Machining (Large or Small Format; Multiple 5-axis Capabilities)
• Plating (Anodize, Chromate, Nickel, Tin Plate, etc.)
• Finishing (Powder Coating, Painting)
• Marking and Silk-screening

Contract Assembly Services: If required, Cofan has the ability for electromechanical assembly services for our customers. These services include operations such as component assembly, testing, packaging, and quality control, allowing our customers to focus on core activities while ensuring efficient production and high-quality standards.

 

Need something special? Talk to our engineers today!
Scroll to Top