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  • May 15, 2024
  • Reata

Machining vs. Extruding Heat Sinks: Which Option Is Better?

Heat Sinks

Heat sinks are vital elements in many electronic and mechanical systems. These parts manage heat in applications like computer CPUs and medical machinery, preventing them from overheating and malfunctioning.

Heat is transferred from the component into the heat sink and then into the air through vertical fins. The fins increase the surface area from which the heat is released. Heat sinks are made from highly conductive metals like copper to improve efficiency.

Heat sinks often go unnoticed by users because they are located internally, but these small but mighty parts are important to get right. Let’s explore the different approaches to manufacturing them and best practices when ordering these parts. 

When to Extrude vs. Machine Heat Sinks

High-quality heat sinks can be manufactured using two different techniques: extrusion and precision machining. At Reata, we generally prefer extrusion for producing heat sinks because this method is typically more cost-effective and consistent. However, machining is still a viable alternative in some scenarios.

Extruding heat sinks

Rows of identical parts with a uniform cross-section are ideal for extrusion. Extruding heat sink fins creates nearly complete shapes requiring minimal complex CNC machining.

We often order ready-made parts for standard heat sink designs from a trusted manufacturing partner specializing in heat sink extrusion. We then make final adjustments using our precision machining capabilities. 

This strategy saves customers significant time and money. A heat sink manufacturer can deliver the initial parts quickly and affordably, and customers will only pay the premium precision machine shop price for minimal machining.

For complex heat sink designs, we can work with you and the extrusion house to ensure a manufacturable design. Bringing us into the process can help minimize the lead-time from design to production.

Machining heat sinks

Generally, we don’t recommend machining heat sinks.

Machining heat sinks from billet is a time-consuming process that requires multiple passes and material removal using a mill. Creating the channels between the fins is highly complex and challenging, even with our cutting-edge machines. The increased tooling requirements, machining time, and labor translates to higher customer costs. 

However, machining may be the best option if the heat sink has complex geometric dimensions. In this case, extruding the part is impractical, and machining is more efficient.

3 Important Considerations for Efficient Heat Sink Manufacturing

Whether your heat sinks are extruded or machined, here are three pieces of advice that apply to both processes:

1. Plan ahead

Heat sinks can have long lead times because not many shops specialize in manufacturing them. Be sure to factor in these lead times when placing an order. When in doubt, engage early.

If you know you will need heat sinks on a recurring basis, we highly recommend expediting the process by placing a blanket order. Reata will hold the additional heat sinks and only charge you for the raw materials up front. 

When you place an order, we’ll already have them in our shop, slashing the lead time by up to 4x! We’ll charge you for our additional machining on a per-order basis.

2. Consider materials

You might be tempted to opt for a cheaper material to cut costs, but the material plays a significant role in the functionality of heat sinks. Choosing a metal with high thermal conductivity, like copper or aluminum, is essential for efficient absorption and release of heat away from sensitive components.

3. Don’t overdesign

At Reata, we strongly believe in the minimum viable product (MVP) approach. Overdesigning parts often increases costs and lead times without improving functionality. 

An example of overdesigning is creating channels with square corners. This choice doesn’t affect the part’s functionality, and machining square inner corners is a time-consuming process. You can save time and money by allowing radii in channels.

Our engineers are ready to assist you with more Design for Manufacturability tips to decrease costs while maintaining superior functionality.

Why Choose Reata as Your Precision Machine Shop Partner?

Reata goes above and beyond to meet customer needs. 

We work with customers to optimize the manufacturability of new and existing designs. Our experienced engineers advise customers on whether extrusion or machining is the best approach based on the part’s design. We provide multiple quotes to help customers compare prices and make informed decisions.

We have long-lasting relationships with extrusion houses, and we leverage these partnerships to ensure parts arrive on time. Our precision machine shop has considerable machining capabilities and can manufacture heat sinks ranging in size from 0.5” to 24”.

There are many important manufacturing considerations regarding heat sinks. Fortunately, our expertise is at your disposal! We encourage you to engage early in the process so we can create an optimal plan of action and ensure you get the parts you need.

Request a quote to get started.

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