Heatsinks · Assemblies
Heatsink assemblies
We deliver complete heatsink assemblies — finned base, heat pipes, fans, insets and fittings — built, tested and ready to bolt in, not a box of loose parts you have to join yourself.
From part to module
A heatsink assembly combines your chosen fin construction with value-added steps: pressed or soldered heat pipes, mounted fans or blowers, machined insets and bus bars, welded fluid fittings and protective anodize. We own the build so you receive one inspected module from one supplier, with one acceptance point instead of several loose components to source and align.
The base can be extruded, skived, bonded or CNC machined — see the relevant heatsink type — and we add only what the thermal job needs.
What we add
- Heat pipes / vapor chambers
- Fans & shrouds
- Machined insets, bus bars
- Welded fittings (FSW/TIG)
Test method and acceptance set with you per module.
How a heatsink assembly is built
- Base construction. The finned base is extruded, skived, bonded or CNC machined to the thermal spec.
- Integrate heat pipes. Pipes are bent, flattened and bonded or soldered into the base where extra spreading is needed.
- Mount fan / blower. An active heatsink gets a fan or blower and shroud fixed to the fin stack.
- Add insets & fittings. Bus bars, machined inserts and welded fluid ports are added per the module drawing.
- Finish. Anodize or coating is applied; surfaces that meet the device are kept flat and clean.
- Test. Fit, leak (if fluid) and a thermal spot-check confirm the module before it ships.
Capability & typical specs
Numbers below are typical; confirm exact limits and test level against your module drawing.
| Parameter | Typical capability |
|---|---|
| Base construction | extruded / skived / bonded / CNC |
| Add-ons | heat pipes, fans, insets |
| Join | weld, bond, press, screw |
| Fan type | axial / blower, per spec |
| Test | fit / leak / thermal spot-check |
Active heatsinks
An active heatsink pairs a finned sink with a fan or blower to force air through the fins. Forced convection moves far more heat than natural convection in the same footprint, so an active assembly is the step between a passive finned sink and a liquid cold plate. We specify the fan by your airflow and noise limit and fix it to the stack with a shroud so the air actually crosses the fins. Use active cooling when a passive sink would be too large or run too hot, but liquid is not yet justified.
Heat pipe integration
A heat pipe heatsink uses sealed pipes that spread heat by evaporation and condensation inside — moving heat from a small hot spot to a larger fin area with almost no drop. Pipes are bent and flattened to fit the envelope, then bonded or soldered into the base. They are the bridge when the device is small and the available fin area is offset from it: a tightly packed IGBT, an LED array, or a sealed box where the fins sit away from the source. We size pipe count and layout to the hot-spot power. Heat pipes are standard copper sintered-wick types — 6 and 8 mm outside diameter, lengths to about 200 mm, each carrying roughly 40–80 W — sourced from qualified suppliers in the Foshan–Shenzhen supply chain; custom diameters and flat-plate vapor chambers are available on request.
Assembled module vs loose parts
| Need | Best choice |
|---|---|
| One inspected part to bolt in | Assembled module |
| Lowest cost, in-house build | Loose finned sink |
| Hot spot far from fins | Module with heat pipes |
| High density, tight space | Active or liquid module |
A module trades a little cost for a single acceptance point and a known thermal result — useful when the sink is on your critical path.
Where heatsink assemblies are used
Power supplies
Enclosed supplies with a fan-mounted sink and bus-bar insets, built and tested as one.
LED & lighting
Arrays using heat pipes to move heat to remote fins behind the fixture.
EV charging
Charge-point modules combining finned base, pipes and welded coolant fittings.
Medical & telecom
Quiet, sealed modules where a known thermal result matters more than part cost.
Thermal & test notes
Design for an assembly
- Send the full module drawing. We split it into make-versus-buy and quote the whole build.
- Define acceptance early. State the thermal test (resistance or power/ΔT) and any leak or fit check so we build to it.
- Fix the interface. Flatness and TIM at the device face decide how much heat reaches the sink — call it out.
- Size the fan to the limit. Airflow and noise both matter; we pick axial or blower from your envelope.
- Mark hot spots. Heat-pipe layout follows the source, so show where heat enters.
How to specify an assembly
Send the module drawing with thermal target, airflow or coolant, and acceptance criteria. If you have loose parts already, tell us which to source and which you provide. We return a build plan, a DFM note and a quote — and we can fold in a cold plate or welded step where the module needs it.
Frequently asked questions
Active or passive heatsink — which?
A passive (finned, no fan) sink is simpler and silent and fine at low power. An active heatsink adds a fan or blower to force air, moving much more heat in the same space. Choose active when a passive sink would be too large or run too hot but liquid cooling is not yet justified. We size the fan to your airflow and noise limit and shroud it so air crosses the fins.
What does a heat pipe do in a heatsink?
A heat pipe spreads heat from a small hot spot to a larger fin area with almost no temperature drop, by evaporation and condensation inside a sealed pipe. It lets the fins sit away from the source — useful for a tightly packed device or a sealed box. Pipes are bent, flattened and bonded or soldered into the base; we set count and layout from the hot-spot power.
Do you test the assembled module?
Yes, to the level you set. Every module gets a fit check; fluid versions get a leak test; and we can run a thermal spot-check against your resistance or power/ΔT target. Define the acceptance criteria up front so the build is made to pass them, not inspected after.
Can you build a module around our loose parts?
Often yes. Send the module drawing and tell us which parts you supply versus want us to make — fins, pipes, fans, insets, fittings. We split make-versus-buy, source what's missing, assemble and test the whole, and return one inspected unit.
What do you need to quote a heatsink assembly?
The module drawing with thermal target, airflow or coolant, and acceptance criteria. A complete drawing gets the tightest quote; describe the load and the parts you have and we propose the build, DFM notes and price.
Quote a heatsink assembly
Send the module drawing — we build and test to spec.