Premier Die Cast Heat Sink Manufacturer

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Die Cast Heat Sink

Die cast heat sinks are made by pouring molten metal into a mold. The mold is designed to create the desired shape for the heat sink, and it also imparts a smooth finish to the metal. After the metal has solidified, it is removed from the mold and allowed to cool.

Die casting is a highly efficient manufacturing process that can produce parts with complex shapes. With die casting, heat sink fins can be incorporated into a frame, housing or enclosure, so heat can be transferred directly from the source to the environment without additional resistance. When used to its full potential, die casting provides not only excellent thermal performance, but also significant savings in cost.

Die Cast Heat Sink Manufacturing Process Video

Features of Die Cast Heat Sink

High pressure die cast heat sinks are a cost effective alternative for high volume applications, the features are:

  • Metal parts with complex shapes, clear contours and thin-walled deep cavities can be manufactured. Because the molten metal maintains high mobility in high pressure and high speed, it can produce metal parts which other process can’t
  • High dimensional accuracy, up to IT11-13, sometimes up to IT9, surface roughness of Ra0.8-3.2um, good interchangeability.
  • High material utilization. Due to the high precision of die-casting, only a small amount of machining is needed, some die-casting can be directly assembled and used. Its material utilization rate of about 60% – 80%, the utilization rate of the blank up to 90%.
  • High production efficiency. Due to the high-speed filling, short filling time, metal also solidified quickly, fast operation cycle speed, die-casting has the highest productivity, suitable for mass production.


Some Successful Die Cast Projects


Die Cast Heat Sink Housing

Material: ADC12

Process: Die cast + CNC machining 

Finish: Powder coating

Quality Control: Calliper, CMM


Die Cast Heat Sink For Led Lighting

Material: ADC12

Process: Die casting

Finish: Powder coating, no accumulated powder is allowed

Quality Control: Calliper, CMM

Die Cast Heat Sink For Communication

Material: ADC12

Process: Die casting + CNC machining

Finish: Powder coating

Quality Control: Calliper, CMM

Die Cast Heat Sink Combine Forge Heat Sink by Friction Stir Welding For Automotive Inverter Housing

Material: Aluminium type EN AC 44300 (AlSi12(Fe)(a)

Process: Die cast + Cold Forge + FSW + CNC machining 

Finish: Degrease

Quality Control: 100% leakage test, CMM

Die Cast Heat Sink With Heat Pipe

Material: ADC12 + Heat Pipe

Process: Die cast + Soldering + CNC machining 

Finish: Degrease

Quality Control: 100% on line thermal test, CMM


Die Cast Heat Sink

Material: ADC12

Process: Die casting + CNC machining 

Finish: Degrease

Quality Control: Calliper, CMM

We Cover Your Needs

Pioneer Thermal produce die cast heat sink over 19 years, with the rich experience and industry-leading equipment, it allows us to produce complex shapes with a high degree of precision and repeatability for a variety of applications. We have good experience in Friction Stir Welding cold forged heat sink to die cast heat sink for automotive industry.

Our heat sinks are designed to offer superior thermal performance, and our manufacturing process ensures that each unit meets our high standards for quality and durability. We offer both standard and custom heat sink solutions, our experienced design and manufacturing team can help you custom design a die cast heat sink optimized for your application to maximize heat transfer and cost effectiveness while minimizing weight and ensuring you optimize your die cast tooling investment.

In addition to our die cast heat sinks, we also offer a variety of other thermal management solutions, including extrusion heat sink, skived heat sink, heat pipe heat sink, cold forge heat sink, vapor chamber and liquid cooling systems. No matter what your thermal management needs are, Pioneer Thermal has a solution for you.

Main Processes
  • Extrusion
  • Bonded Fins
  • Skived Fins
  • Snapped Fins
  • Folded Fins
  • Heat Pipes
  • Cold Forge
  • Die Cast
  • Friction Stir Welding Cold Plate
  • Gun Drill Cold Plate
  • Vacuum Brazing Cold Plate
  • Vapor Chamber
Finishing Processes
  • CNC machining
  • Stamping
  • Drilling
  • Tapping
  • Screen Printing
  • Anodizing
  • Powder Coating
  • Electrophoresis
  • E-coating
  • Chromate
  • Passivation
  • Laser Etching
  • Polishing
Finishing Value Added
  • Embedded fans
  • Thermal Grease
  • Phase Change Materials
  • Gap Filler Pads
  • Screws
  • Springs
  • Clips
  • Embedded Heat Pipes
  • Back Plates
  • PEMs
  • Standoffs
  • Dielectric pads
  • Compounds


Design Service
  • Icepak, ansys, EFD, Flotherm for thermal design
  • Computer Aided Design (CAD) and PROE for structure design
  • Weight reduction
  • Eliminate fans for a passive solution
  • Projected cost of the final product
Prototype And Testing
  • Rapid prototype build
  • CMM and precision measuring tools
  • Thermal measurement devices
  • Thermal chambers
  • Shock testing and cycling
  • Salt spray testing for corrosion analysis
Serial Order Production
  • State of the art machinery
  • Strict quality control
  • Latest production techniques
  • Focus on continuous improvement
  • Robust packaging design

We'd Love To Hear From You

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Hi partner, no matter you need new design & simulation for your new project, or you need heat sink manufacturing service for current on-going project, we are at your service.

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