Cold Forged Heatsinks

Capabilities, Benefits, and Applications

What is Cold Forging?

Cold forging is a high-pressure metal forming process performed at or near room temperature. Aluminum (commonly 1050, 1070, 1100, or selected 6xxx alloys) is plastically deformed in precision dies to create dense, near-net-shape heatsinks—often with integrated fins, pins, or bases—without melting the material.

Capabilities

• Complex geometries in one operation
  Dense pin-fin arrays, tapered fins, stepped bases, and integrated mounting features can be formed without secondary assembly.
• High fin density & aspect ratios
  Enables closely spaced fins or pins that are difficult to achieve with machining or extrusion.
• Excellent surface flatness
  Produces flat, smooth bases suitable for direct interface with CPUs, power modules, or vapor chambers.
• Material integrity
  Grain flow follows the part shape, improving strength and durability.
• Scalable production
  Ideal for medium-to-high volumes with consistent repeatability once tooling is established.

Benefits

• Superior thermal performance
  Cold work densifies the metal and aligns grain structure, improving thermal conductivity versus cast parts.
• No porosity
  Unlike die casting, cold forging yields dense parts—better heat transfer and reliability.
• Lower material waste
  Near-net shaping minimizes scrap compared with CNC machining.
• Cost efficiency at volume
  Fewer secondary processes and fast cycle times reduce per-part cost in production.
• Mechanical robustness
  Higher strength allows thinner fins and lighter designs without sacrificing durability.
• Clean, eco-friendly process
  No melting, fewer emissions, and reduced energy use compared to hot processes.

Applications

• CPU, GPU, and chipset cooling
  High-performance pin-fin or finned bases for air-cooled and hybrid solutions.
• Power electronics
  IGBTs, MOSFETs, inverters, power supplies, and motor drives.
• Automotive electronics
  EV power modules, onboard chargers, ADAS controllers, LED headlamps.
• Telecom & networking
  Base stations, routers, optical modules requiring compact, efficient cooling.
• Industrial & medical equipment
  Reliable thermal solutions for harsh or continuous-duty environments.
• LED lighting
  Dense fin designs to maintain lumen output and extend LED lifetime.

When to Choose Cold Forged Heatsinks

Choose cold forging when you need maximum thermal performance, compact size, high fin density, and production-ready consistency—especially where die casting porosity or extrusion geometry limits are unacceptable.