Custom Extruded Aluminum Heat Sink Manufacturer
HTS-ALU is a manufacturer of custom extruded aluminum heat sinks. We support die design from drawings or samples, aluminum heat sink extrusion, CNC milling, drilling, and surface finishing for LED lighting, power electronics, and industrial thermal management applications.
Extruded Aluminum Heat Sink Overview
An aluminum heat sink is used to dissipate heat from electronic components and systems. Due to aluminum’s thermal conductivity, lightweight properties, and extrudability, aluminum heat sinks are widely used in LED lighting, power electronics, and industrial applications.
Why Heat Sink Extrusion Is the Preferred Manufacturing Method
Heat sink extrusion allows aluminum heat sinks to be produced with continuous fin structures and consistent dimensions along the full length. Compared with machining-only methods, an extruded heat sink is more efficient and economical for long profiles and medium to large production volumes.
Extruded Aluminum Heat Sink Profile Types
Extruded aluminum heat sinks can be manufactured in a wide range of profile shapes to meet different thermal, structural, and installation requirements. Common designs include straight fin heat sinks, round and circular profiles, large-format heat sinks, enclosures, and special cross-sections for electronics and LED applications. All profiles are produced through extrusion, allowing consistent geometry along the length and flexibility for custom designs, machining, and surface finishing.
Alu Heat Sink Extrusion
HTS-ALU is equipped with 40 extrusion production lines, enabling us to handle large-scale orders with ease. Our largest extrusion machine has a capacity of 6,000 tons, allowing us to manufacture both small and large heat sinks to meet diverse customer needs. This extensive capacity ensures timely delivery and high-quality products for our clients.
Extruded Heat Sink Machine Process
At our factory, we specialize in the machining of extruded aluminum heat sinks, equipped with advanced machinery to enhance the functionality and versatility of our aluminum profiles. We operate two precision cutting machines, along with eight CNC machines, including both 4-axis and 5-axis models, capable of processing lengths up to 7500 mm. Our comprehensive capabilities include precision cutting for exact lengths and clean edges, as well as punching and threading for essential modifications. Slotting is also performed to ensure compatibility with various components. Additionally, our assembly services guarantee that all parts are correctly joined and ready for immediate deployment across a wide range of applications.
Precision Cutting: We can accurately cut aluminum heat sinks to the exact lengths specified by our customers, ensuring a perfect fit for their applications.
Tapping and Threaded Holes: Our facilities are equipped to create threaded holes, allowing for the easy installation of fasteners in the heat sinks.
Drilling: We offer precise drilling services to create holes for mounting or airflow, tailored to meet specific design requirements.
Milling: Using customer-provided drawings, we can mill the extrusions to achieve the desired complex structures and designs.
Welding: We provide welding services, such as attaching studs or other components to the heat sinks, enhancing their functionality.
Engraving and Logo Application: Custom engraving or logo application is available through laser engraving or silk screening, adding a personalized touch to the products.
Surface Finishes for Aluminum Heatsinks
The surface treatment of aluminum heat sinks is essential for improving their performance and durability. It enhances corrosion resistance, extends product lifespan, and boosts thermal conductivity for better heat dissipation. Surface treatments also improve aesthetics through colored anodizing or painting, reduce friction to minimize wear, and increase adhesion of coatings for greater durability. Additionally, treated aluminum heat sinks can meet industry standards, creating new market opportunities. Overall, effective surface treatment significantly enhances product value and customer satisfaction.
Anodizing
Anodizing creates a durable, corrosion-resistant aluminum oxide layer and can also add color for aesthetic appeal. However, this oxide layer is an insulator, which can significantly reduce the electrical conductivity of the aluminum. The thickness of the anodized layer influences this effect, so thinner anodizing may mitigate conductivity loss compared to thicker coatings.
Powder Coating
Powder coating applies a layer of powder paint to the heat sink, which is then heated to form a protective coating. This method improves corrosion resistance and offers various color options. Spray coating creates a protective layer by spraying a liquid coating, enhancing durability and appearance.
Other Surface Treatments
Chemical plating deposits a film on the aluminum surface to improve conductivity and corrosion resistance, while passivation forms a thin protective film that further enhances corrosion resistance. These surface treatments improve the durability, performance, and aesthetics of aluminum heat sinks, making them suitable for various applications. Choosing the right treatment is essential for the heat sink’s long-term effectiveness.
Skived Fin Heat Sink
In some applications, the fins of a heat sink need to be very tall, thin, or densely spaced. These structures are often difficult or impossible to produce through standard aluminum extrusion processes. When the required fin height or density exceeds extrusion limitations, skived fin technology can be used as an alternative manufacturing method.
Skived fin heat sinks are produced by mechanically slicing and lifting thin fins from a solid aluminum block, creating continuous fins with excellent thermal performance. To complement our extrusion manufacturing capabilities, HTS-ALU also works with skived fin equipment, allowing us to support customers whose heat sink designs cannot be achieved by extrusion alone.
Our Factory
HTS-ALU is a custom aluminum extrusion manufacturer based in China. Our facility operates 40 aluminum extrusion lines, including presses up to 6000 tons, enabling the production of a wide range of aluminum heat sink profiles. We also provide surface finishing and CNC machining services, and support custom logo marking and packaging for OEM projects. In addition to extruded heat sinks, we are equipped with skiving machines to produce aluminum heat sinks with high-density fins that cannot be achieved through extrusion alone.
Extruded Aluminum Heatsink Solution
HTS-ALU provides one-stop aluminum heat sink solutions, from drawing review and die design to extrusion, machining, and finished products.
- Over 20 years of industry experience ensures the mastery of high-quality aluminum heat sink extrusions.
- An extensive production capacity of 40 extrusion lines allows for the efficient fulfillment of large-scale orders with up to 6,000 tons of processing capability.
- Specialized surface treatments like oxidation, colored anodizing, and powder coating elevate our products, enhancing both performance and aesthetics.
- Advanced in-house machining capabilities enable precision milling, threading, welding, and custom engraving for logos or designs.
Aluminum Extruded Heat Sink Applications
Extruded aluminum heat sinks are widely used in various applications to manage and dissipate heat efficiently. They are commonly found in electronics to cool components like CPUs, GPUs, and power modules. In the automotive industry, they help regulate temperatures in electric vehicles and other systems. They are also crucial in LED lighting to extend the lifespan of the bulbs. Additionally, extruded aluminum heat sinks are used in renewable energy systems, such as solar inverters and wind turbines, as well as in industrial machinery to enhance performance and durability.
Aluminium Motor Body
Aluminum extrusions are ideal for motor bodies due to their superior strength-to-weight ratio and excellent thermal conductivity, which are crucial for electric and hybrid vehicles requiring efficient heat dissipation. These extrusions facilitate the creation of complex, precise shapes, optimizing space and enhancing vehicle performance through weight reduction. Additionally, aluminum’s natural corrosion resistance and durability ensure long-term reliability and lower maintenance costs in harsh environments.
Electronics and Computing Heat Sink
Aluminum heat sinks are extensively used in the electronics and computing industry to prevent overheating in devices such as CPUs, GPUs, and power transistors. By efficiently dissipating heat, these extrusions ensure that electronic components operate within safe temperature limits, enhancing performance and preventing premature failure.
LED Lighting Heat Sink
As LED technology continues to advance, managing heat becomes increasingly important to maintain the efficiency and lifespan of LED lights. Aluminum heat sink extrusions are used in LED lighting fixtures to absorb and dissipate the heat generated by LEDs, thereby preventing overheating and ensuring stable operation.
Telecommunications Heat Sink
Telecommunication equipment such as high-frequency servers, routers, and other infrastructure components rely on aluminum heat sinks to manage heat. These devices often operate continuously and generate significant amounts of heat, which if not properly managed, can lead to system failures and reduced efficiency.
Industrial Machinery Heat Sink
Heat sinks in industrial applications often need to handle extreme conditions and high power devices. Custom-designed extrusions are used to meet specific requirements and ensure machinery operates efficiently and safely.
RFQ of Extruded Aluminum Heat Sink
To start a custom aluminum heat sink extrusion, we need a drawing, 3D file, or sample. Key details include the profile cross-section, fin height and spacing, length, machining requirements, surface finish, and estimated order quantity. Our engineers can review and optimize the design for extrusion if needed.
- 6061: A versatile alloy with higher strength, suitable for structural and transportation applications.
- 6063: Known as the “architectural alloy,” it offers excellent surface finish and is widely used for decorative and structural purposes.
- 6060: Similar to 6063 but with slightly lower strength, ideal for intricate and thin-walled profiles.
- 6066: A high-strength alloy within the 6xxx series, often used in more demanding structural applications.
- 6082: A strong alloy with better mechanical properties compared to 6061 and excellent corrosion resistance, commonly used in high-load structural applications and in marine environments.
The 7xxx series alloys, such as 7075, are used in applications requiring extremely high strength and performance, such as aerospace and high-end engineering projects. However, they have lower corrosion resistance when compared to 6xxx alloys and are therefore less commonly used for general extrusion applications.
While 1xxx, 3xxx, and 5xxx series alloys can be extruded, they are generally used infrequently for extrusion due to their lower strength or other limitations compared to 6xxx and 7xxx alloys. These series are mainly used in specialized applications. Additionally, if extrusion products from these series are requested, higher minimum order quantities (MOQ) are typically required for custom production, as their demand is relatively low.
HTS-ALU provides in-house extrusion die design based on customer drawings or samples. Each profile is reviewed for extrudability, fin geometry, and dimensional stability to ensure reliable heat sink extrusion and consistent mass production.
The most commonly used alloy for aluminum heat sink extrusion is 6063, due to its excellent extrudability, surface finish, and thermal performance. Other alloys such as 6060, 6061, and 6005 can also be used depending on strength, machining, or application requirements.
Heat sink extrusion is ideal for straight fin and continuous fin geometries. Fin height, thickness, and spacing are subject to extrusion limits, which vary by profile size and alloy. Our engineers evaluate each design to balance thermal performance with extrusion feasibility and cost efficiency.
MOQ depends on the profile size, alloy, and complexity. Typical minimum order quantities range from 500 kg to 2000 kg per profile. For quantities below standard MOQ, production may still be possible with an additional material loss or setup cost.
Extrusion die cost depends on the profile size and complexity. For many standard heat sink profiles, die costs are relatively moderate. In some cases, die costs can be partially or fully refunded after reaching an agreed cumulative order volume.
Custom extruded aluminum heat sinks are widely used in LED lighting, power supplies, inverters, power electronics, motor drives, and industrial equipment, where reliable thermal management and scalable production are required.
Extruded heat sinks provide continuous fin geometry, high dimensional consistency along the full length, and lower unit cost for medium to large production volumes. For more complex designs, heat sink profiles can be first produced by extrusion and then finished with CNC machining, combining the efficiency of extrusion with the flexibility of machining. This hybrid approach allows complex features to be achieved while maintaining cost-effective and scalable production.
Copper has a higher thermal conductivity than aluminum. The thermal conductivity of copper is typically around 390–400 W/m·K, while aluminum heat sinks usually have a thermal conductivity of approximately 200–235 W/m·K, depending on the alloy. This means copper can dissipate heat more efficiently on a material level.
However, copper is significantly more expensive, heavier, and more difficult to manufacture, especially for complex fin structures. Aluminum heat sinks offer much better manufacturability through extrusion, lower cost, and lighter weight. For most thermal management applications, aluminum heat sinks can meet heat dissipation requirements while enabling cost-effective, scalable production, making them the preferred choice in LED, power electronics, and industrial applications.
About HTS-ALU
HTS New Materials (Jiangxi, China) is a leading aluminum extrusion manufacturer with 40+ advanced lines and presses up to 6,000 tons. We supply profiles for construction, industrial uses, and premium doors/windows, including thermal-break profiles.
Capabilities include anodizing, powder coating, fluorocarbon coating, and wood-grain transfer. We also offer end-to-end machining and fabrication: CNC, milling, punching, drilling, threading, precision cutting, welding, and assembly—delivering ready-to-use, project-specific solutions.
Hot-Selling Products
Custom Extrusion Steps
- Share your CAD/STEP files or a physical sample.
- We create manufacturing drawings.
- You review and approve the drawings.
- We manufacture the extrusion die.
- We run a trial extrusion.
- You validate and sign off the samples.
- We begin mass production.
- Typical extrusion lead time is about 15 days.
- Extra time is added for finishing or machining.
- We perform in-process inspections.
- We conduct final inspections before shipment.
- We protect each profile to prevent abrasion.
- We pack per your requirements.
- We arrange shipment by sea, air, rail, or multimodal.
Alloys for Extruded Profiles
- 6063 (T5/T6)
- 6061 (T6/T6511)
- 6060 (T5)
- 6005/6005A (T5/T6)
- 6082 (T6)
- 6101 (T6/T61)
- 7075 (T6/T73)
- 2024 (T351)
Packing Options
- Single-piece protective film separation
- Blister packaging
- Carton packaging
- Wooden crate packaging
- Palletization
