Heatsink Types Commonly Used in ITAR / Defense Programs
1. Extruded Aluminum Heatsinks
Description:
Precision-extruded aluminum (typically 6061 or 6063) used for passive or forced-air cooling in rugged electronics.
Key Benefits:
- Proven, repeatable performance
- Lightweight with excellent strength-to-weight ratio
- Cost-effective for long program lifecycles
- Easily machined for secure mounting and sealing
Typical ITAR / Defense Applications:
- Ruggedized computers
- Secure communication systems
- Power conversion electronics
- Command and control modules
2. Cold Forged Heatsinks
Description:
High-pressure forming creates dense material structure and high fin density for compact, high-performance cooling.
Key Benefits:
- Very low thermal resistance
- High mechanical strength
- Compact size for space-constrained platforms
Typical ITAR / Defense Applications:
- Avionics modules
- UAV and aerospace electronics
- Portable defense systems
- High-power RF electronics
3. Bonded Fin Heatsinks
Description:
Fins bonded or brazed to a base to maximize surface area beyond extrusion limits.
Key Benefits:
- High heat dissipation capability
- Flexible fin geometry
- Ideal for high-power electronics
Typical ITAR / Defense Applications:
- Radar subsystems
- Electronic warfare systems
- Signal processing units
4. Die Cast Aluminum Heatsinks
Description:
High-pressure die casting enables complex shapes with integrated housings, airflow paths, and mounting features.
Key Benefits:
- Structural and thermal integration
- Rugged and vibration resistant
- Suitable for sealed or vehicle-mounted systems
Typical ITAR / Defense Applications:
- Ground vehicle electronics
- Surveillance systems
- Missile and launcher support electronics
5. Heat Pipe & Vapor Chamber Assemblies
Description:
Advanced heat-spreading technologies used to move heat rapidly away from high-flux components.
Key Benefits:
- Excellent temperature uniformity
- Supports high power density designs
- Enables sealed or fanless architectures
Typical ITAR / Defense Applications:
- Avionics processors
- Radar and RF amplifiers
- Secure computing platforms
6. Liquid-Cooled Cold Plates
Description:
Liquid cold plates remove large thermal loads using circulating coolant.
Key Benefits:
- Extremely low thermal resistance
- Continuous-duty capability
- Stable operation in extreme environments
Typical ITAR / Defense Applications:
- High-power radar arrays
- Directed-energy systems
- Electronic warfare platforms
Defense Applications & Thermal Requirements
| Defense Platform | Power Density | Thermal Solution |
| Secure communications | Low–Medium | Extruded / cold forged |
| Avionics systems | Medium | Cold forged / heat pipe |
| Radar & RF systems | High | Bonded fin / liquid cold plate |
| Vehicle electronics | Medium–High | Die cast / bonded fin |
| Directed energy | Very High | Liquid cold plate |
ITAR & Defense Manufacturing Requirements
- ITAR-compliant facilities and personnel
- Controlled technical data access
- Full material and process traceability
- Documented quality systems (AS9100 / ISO)
- Strict export control and program security
Key Design Considerations
- Resistance to shock, vibration, and thermal cycling
- Operation across wide temperature extremes
- Long service life and mission reliability
- Compatibility with sealed and rugged enclosures
- Secure supply chain and domestic manufacturing