Extruded heat sinks are made by first heating aluminum until it is soft, then pushing the softened metal through a machined die in the shape of the heat sink profile. Once the length of the heat sink has been reached, the extruded heat sink is cut from the die, and is then cooled and prepared for use. This process creates a solid structure that can be bonded directly to the heat source. After the aging process, the material is cut to the final length and any final fabrication (holes, pockets, or other secondary machining) can be done. Extruded heat sinks are usually supplied with a “finish” such as anodizing which can enhance its thermal performance. The heat sinks can also be supplied with a chromate finish which provides some corrosion protection or can be used as a primer before a final paint or powder coating is applied. While each extruded shape is unique to the requirements that it was designed for, extruded heat sinks are the most cost-effective cooling solution.
This heat sink type is the easiest to manufacture, due to having fewer steps in the manufacturing process. Also, because the fins and the heat sink base are extruded as one unit, the thermal flow path is uniform, ensuring excellent thermal conductivity from the heat source to the fin surface. Additionally, extruded heat sinks have higher structural stability.The flatness and surface roughness is a critical component of the manufacturing process, as this determines the effectiveness of the thermal interface with the heat source.Extruded heat sinks are the most common heat sink used for thermal management today. The most common aluminum alloy is 6063-T5, but other 6XXX alloys can also be examined as needed.
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