We cut, face and drill extruded aluminum heatsink profiles so the base sits flat and the fins stay open. One prototype or 10,000 parts, machined to ±0.005 mm in Dongguan.
An extruded bar cools unevenly and bows along its length. Skip the facing pass and the gap to the chip or IGBT pad widens. Thermal resistance climbs, junction temperature rises, and the part fails the burn-in test.
Cold saws and abrasive blades push aluminum into the fin gaps. Once the fins fold over, the surface area is gone. You cannot bend them back without cracking the extrusion, so the profile is scrapped.
A 1,000 mm extrusion clamped in a short vise will spring when the drill bites. Hole positions shift 0.3 mm or more, mounting screws bind, and the assembly line stops to rework the bracket.
Bare extrusion from two billet batches shows different grain and color. Mixing them in one enclosure looks wrong to the customer. Anodizing hides some of it, but only if the surface prep is consistent.
Cut, face, drill and finish in one shop, with the profile and the machining planned together.
Extruded aluminum comes off the press with internal stress. When you remove stock from one side only, the bar bows toward the cut. We face both sides in the same setup on a 3-axis mill, taking light passes so the part stays cool.
For a heatsink that bolts to a metal chassis, we hold base flatness across the full length and check it on a surface plate. Contact area is what moves heat. A 0.05 mm bow over 200 mm can cost more thermal performance than a change of alloy.
Fin pitch of 2 mm to 8 mm is common on extruded profiles. Drill and tap operations run between the fins, so we plan tool reach and coolant flow before the first cut. A tap that rubs instead of cutting will tear the fin wall.
Heat pipes, mounting studs and threaded inserts all need a clean seat. We machine the bore to size, then press or thread the insert in-house. Nothing gets sent out and lost between vendors.
Match the profile and alloy to the load, not to what is already on the shelf.
| Profile type | Typical use | Why it fits |
|---|---|---|
| Straight fin, 2–4 mm pitch | LED arrays, dense boards | High surface area per mm of width |
| Wide gap, 6–8 mm pitch | Natural convection enclosures | Air moves through without a fan |
| Bonded fin block | High watt density, small footprint | Skived fins on a machined base |
| Round or domed profile | Cylindrical housings, motors | Wraps the heat source evenly |
| Plate with embedded pipe | IGBT and inverter modules | Spreads heat before the fins |
Facing, drilling and slotting on extruded bars up to 4,000 mm. The workhorse for base prep and hole patterns.
Adds a rotary table for angled holes and radial features on round or domed heatsink profiles.
One setup for contoured fin edges and compound faces. Sixteen simultaneous 5-axis centers available.
Mill-turn centers handle heatsink bosses and threaded studs in a single cycle.
Clear or black anodizing, hardcoat and conductive finishes. Bead blasting before coating for even color.
One-off machined samples for thermal testing before you commit to a production run.
Numbers below are what our machines and inspection can hold.
| Item | Capability |
|---|---|
| Standard tolerance | ±0.005 mm (±0.0002 in) |
| Maximum part length | 4,000 mm |
| Large travel envelope | 4,000 × 400 × 150 mm |
| Fine surface finish | Ra 0.2–0.8 μm |
| High surface finish | Ra 0.8–1.6 μm |
| Rotary table | Ø400 mm |
| Order quantity | One prototype to 10,000+ parts |
| Inspection | 100% before shipment, reports on request |
Three wholly-owned plants and 150 technicians in Dongguan, plus a Singapore factory for regional delivery.
Complex fin and face geometry in one setup, so you do not stack tolerance across three operations.
Angled holes and radial work on round profiles stay on one machine and one datum.
Held on production heatsinks, not just on a first article pulled from a cold machine.
We review your drawing for fin clearance and base flatness, then send a quote with notes.
Material in stock and programs ready means chips fly the day after you approve the quote.
Inverter and charger heatsinks need flat bases and vibration-proof threads.
Cleanable surfaces and no trapped chips between close fins.
LED and power supply profiles cut to length with drilled mounting patterns.
Long profile heatsinks for drives and control cabinets.
Yes. Send the cut length, the profile drawing and the material lot. We will confirm flatness after facing and flag any wall that is too thin to hold in the vise.
If the profile is not released yet, we can quote from an extruded bar we source, or machine a sample from plate for early thermal testing.
6063 is the usual choice for extrusion. It flows well through the die, takes anodizing evenly, and has enough thermal conductivity for most LED and power electronics work.
6061-T6 is stronger but extrudes less cleanly in thin fins. We use it when the heatsink is also a structural bracket. 6061 and 6063 are both in our stock list.
We face both sides in one setup, take light passes, and let the part cool before the finish cut. Clamping pressure is set so the bar is held, not squeezed.
After machining, the base is checked on a surface plate. Any reading outside the drawing tolerance goes back on the machine.
We do clear, black, hardcoat and conductive anodizing. Standard anodizing adds a thin oxide layer that slightly insulates, which is fine for most convection-cooled parts.
For a heatsink that contacts a pad directly, specify masking on the mating face or choose a conductive finish. Tell us the interface and we will note the masking on the traveler.
There is no minimum. We run one prototype for thermal testing and the same part number as a 10,000-piece production order.
Setup cost is the same either way. The per-part price drops with volume, but the process does not change.
Quotation and a free DFM analysis come back within 12 hours. Production can start within 24 hours of approval.
Standard parts ship in 3–5 days. If your profile needs to be extruded first, that lead time sits outside our machining window, so plan the die order early.
We machine the bores and seats for heat pipes, then press or thread the inserts in-house. Fan mounting holes and standoffs are cut in the same setup as the fins.
If you want the full sub-assembly shipped as one unit, say so at quote time so we can plan incoming inspection for the bought-in parts.
Uploads are secure and confidential. We can sign your NDA or provide ours before you send drawings.
Tooling, programs and inspection data stay tied to your part number and are not shared with other customers.
You get a quote and a DFM note on fin clearance and base flatness within 12 hours. No minimum order quantity, 100% inspection before shipment.
12-hour quote100% inspectionNo MOQ
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Upload your 3D model or 2D drawing and get a quotation with a free DFM analysis. Maximum processing size 4,000 mm.
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