Primary process: Die Casting. The full route, materials, tolerances and design tips for a heatsink, with an indicative cost.
Die CastingPrimary process
CastingFamily
8Route steps
+/-0.1mmTypical tol.
A heatsink is primarily made by Die Casting. Die casting forces molten metal, usually aluminium, zinc or magnesium, under high pressure into a hardened steel die. It produces thin-walled parts fast once the die is paid for. Below is the full route to make a heatsink, the materials it suits, the tolerances to expect and the main design points. The route is free, from the finder.
Step by step
How a heatsink is made
The usual route, raw material to finished part. The amber step is where the heatsink gets its basic shape.
Alloy and tooling
Choose the casting alloy for the heatsink and make the pattern or metal die that forms the cavity.
Die Casting
Melt the metal and force it into the die under pressure, then let the heatsink solidify and cool.
Tooling High (steel die) Tolerance ±0.1 to 0.4mm Lead 6 to 10 weeks
Fettling and cleaning
Cut off the gates and risers, grind away the flash, and clean the raw casting.
Machining
Machine the mating faces, bores and datum surfaces to final tolerance: the as-cast surface is too rough for close fits.
Tooling None Tolerance ±0.125mm, to ±0.025mm Lead 1 to 10 days
Hole making
Drill, ream and tap the fixing and functional holes.
Tooling None Tolerance ±0.05 to 0.2mm Lead hours to days
Heat treatment
Stress-relieve or harden the heatsink to reach the strength and hardness the design needs.
Tooling n/a Tolerance can distort Lead days
Surface finish
Plate, anodise or powder coat for corrosion resistance and appearance.
Tooling Low Tolerance adds 0.05 to 0.2mm Lead days
Inspection
Check critical dimensions and, for any part that holds pressure, leak-test before it ships.
Need the real cost for a heatsink? The free route above is yours. Unlock the full dossier to quote and source it.
Where this process typically lands. Tighter is possible with extra operations like grinding, at higher cost.
Materials
Materials for a heatsink
Grade
Why it suits this
Aluminium A380/ADC12
Best castability, good strength
Zinc Zamak 3/5
Low melt, fine detail, long die life
Magnesium AZ91
Lightest structural
Design
Design tips
General pointers. The full design-for-manufacturing list for a heatsink is in the dossier.
Thick/uneven walls.Thin and even them.
Bosses without draft.Add draft.
Cost
What a heatsink should cost
Only pays above ~10k parts; below that, machine from billet or sand cast. The die is the whole economics.
PER-PART COST vs VOLUME
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for a heatsink at your volume, in your currency, are in the dossier.
MODEL EST.
$400 to 900per part at 1 off
A rough ballpark only. The dossier gives should-cost at your exact volume and currency, with the full breakdown.
GET THE FULL DOSSIER
Everything you need to quote and source it
The free route above is yours. To actually put a number on a heatsink and buy it well:
Should-cost at your exact volume in 12 currencies, with the material, processing, tooling and overhead breakdown
Who to source from, typical MOQ and lead time, and the exact RFQ checklist to send
A quote checker that tells you if a supplier quote is fair, and the red flags to watch
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A heatsink is primarily made by die casting. The route is: Alloy and tooling; Die Casting; Fettling and cleaning; Machining; Hole making; Heat treatment; Surface finish; Inspection.
What does a heatsink cost?
It depends on size, tolerance and volume. As a rough ballpark it starts around $400 to 900 per part at 1 off and falls with quantity. The dossier gives should-cost at your exact volume and currency. A model estimate, not a quote.
What material is a heatsink made from?
Common choices are Aluminium A380/ADC12; Zinc Zamak 3/5; Magnesium AZ91.
What is the main process for a heatsink?
Die Casting. High-volume non-ferrous parts with thin walls, fine detail and a good as-cast finish, such as housings and brackets.
See the exact route and should-cost for your part
The free finder maps your part to its process and full route. Pro adds should-cost at your volume, sourcing and an RFQ draft.
