Swaged Heatsinks

Swaged Fin Heatsinks Thermal Solutions

Swaged heatsinks are typically used to dissipate heat from electronic components such as transistors, diodes, and integrated circuits. The swaging process is a manufacturing process used to create these heatsinks. The swaging process involves the following steps:

1. Starting material: The swaged heatsink manufacturing process begins with a cylindrical aluminum extrusion. We work with an extrusion  6000-series aluminum extrusion alloy.

2. Cutting: Our technician cut the extrusion into the desired length using a saw or other cutting tool.

3. Annealing: The extrusion is then heated to a specific temperature and held for a particular amount of time to soften the aluminum and make it more malleable.

4. Swaging: The team place the softened extrusion into a swaging machine. The machine has a series of dies to shape the extrusion into the desired heatsink shape. The dies apply pressure to the extrusion, causing it to deform and take on the form of the dice.

5. Straightening: The swaged heatsink is straightened using a straightening machine. This machine applies pressure to the heatsink to straighten any bends or curves that may have been created during the swaging process.

6. Finishing: The swaged heatsink is then finished by cutting it to the final length, drilling any necessary holes, and applying any essential coatings or finishes.

The swaged heatsink manufacturing process creates heatsinks that are lightweight, durable, and efficient at dissipating heat. In addition, the swaging process allows for complex shapes and designs, making it ideal for creating customized heatsinks for specific applications.

Heat Sinks That Have Been Swaged

Cooling SourceSwaged manufacturing process uses a process similar to forging. Swaging is the technique of shaping metal into a die. Swaged heat sinks manufactured by Cooling Source provide excellent performers. Also, Cooling Source design swaged heatsinks well suited to high-power applications. However, customers find swaged heat sinks bulky and have little airflow control.


Swaged fin

Swaged fins are an excellent high-power solution for forced or natural convection. Swaging cuts and bonds individual straight fins into a grooved base plate. Fins on a zipper/skived or folded fin are usually thicker than those on a zipper/skived or folded fin. Our team, manufacture Aluminum and copper fins mixed on the same swaged heat sink to improve performance without adding weight. 


At Cooling Source, we design Swaged fin heat sinks for physically large applications with modest performance requirements. Individual metal fins are swage (roll-pressed) or pressed to a foundation to create swage fin heat sinks. Then, pressing and deformation are used to glue the pieces together. The real benefit of this heat sink is that it can be employed in massive applications. The main disadvantage is that the production process isn’t as automated for stamped, extruded, or folded fin heat sinks, resulting in a high swaging fin cost.

Cooling Source design swaged fin heatsinks to maximize the surface area in contact with the coolant fluid.

CSI’s manufacture swaged heatsinks from either aluminum or copper metal sheets or extruded. Aluminum costs less than copper. However, copper provides higher levels of thermal conductivity.

Our engineers’ design swaged heatsinks to meet particular needs. Should you have any questions about using swaged heatsinks, our knowledgeable consultants can discuss your specific needs and answer any questions. Choosing the right product for cost, delivery time, and effectiveness is essential. The choice you make can be crucial to your success.

Cooling Source design swaged heatsinks for high-power applications with low thermal resistance. Therefore, customers need forced air cooling for swaged heatsink applications.

Benefits of Swaged Fin

  • Better aspect ratio than thin fin extrusions
  • Doesn’t require interface material between the base and fins.
  • Fins can be as thin as 0.008. “
  • Fins can be 2 inches or higher
  • Environmentally friendlier than soldered fin heat sinks
  • The solid mechanical bond between the base and the fins
  • Excellent process for large heat sinks

Swaged Fin has better thermal resistance than bonded fin heat sinks.

A simple call or e-mail will put you in touch with the experts with your required answers.

Engineering Support

As part of design work, our engineers apply advanced 3D modeling. Also, we are using cutting-edge CFD tools to optimize your heat transfer project. In addition, we provide our customers with a complete cooling solution to meet specific swaged fin heatsinks requirements in a timely and cost-effective manner.

Also, you can count on our Mechanical Engineers to assist with design change and reduce manufacturing costs.


Contact us

swaged heatsink

2021 Las Positas Ct, Ste 101
Livermore, CA 94551
Phone: (925) 292-1293
Fax: (925) 292-5061


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