The production process for cold forged heat sink requires no machining, cutting, or welding, making it more cost effective than extruded or bonded-fin heat sinks. Both fins/pins and base are made from a single piece of metal by forging it into the form by high pressure.
A variety of heat sink fin shapes can be produced, including pin fin heat sinks, plate fin heat sinks, air foil fin heat sinks, round fin heat sinks, and square fin heat sinks. Forged heat sinks can be made with thin round pins or thin fins and high density geometries while benefiting from the thermal conductivity of a uniform piece of metal (no impedance from bonding).
Pin Fin advantages: Erecting a forest of pins from a flat base is a popular way to maximize surface area; they work best when air flows axially along the pins.
Cold forged heatsinks are used to dissipate heat in high powered electronics, multi-chip modules, and in other similar applications.
Forged Heat Sinks conjure up the image of a blacksmith forming metal into a heat sink, but, in today’s modern world, forging is done by compressing a metal, in this case aluminum or copper. Forged heat sinks may be used in a wide variety of applications. They are medium performing heat sinks that are generally inexpensive to make. Their only real limitation is they are somewhat limited in design and air flow management.
Cold forging is a cold working process. Aluminium is squeezed by a press into the closed die, the resultant heat sink taking on the shape of the void in the die. This process is also known as cold heading. Cold forged heat sinks often have high performance compared with other technologies, mainly because any increase to the surface area of a heat sink will almost always result in improved thermal performance. Forged fins can be made almost perfectly straight, allowing for more fins per square inch than in an extruded product. The part is formed under high pressure which controls the grain structure and results in improved thermal performance The fins can also be formed into an elliptical or circular shape enabling airflow from any direction – a big advantage in some applications.