Die Cast Heat Sinks vs Extruded Heat Sinks - Differences

 1. Manufacturing process

The manufacturing process is one of the most notable differences between die casting heat sink and extrusion heat sink. The die casting process involves injecting  molten metal into a mold under high pressure, while the extrusion process involves pushing a metal billet through a die. The die-casting process can produce complex shapes and designs, while the extrusion process is better suited for simpler shapes.

 2. Design flexibility

Design flexibility is another significant difference between die-cast and extruded heat sinks. Due to the use of moulds, die-cast heat sinks can achieve complex shapes and designs. In contrast, extruded heat sinks are limited in design due to the use of a fixed cross-sectional shape for the heat sink.

 3. Cost

Cost is another important factor to consider when comparing die cast versus extruded heat sinks. Die casting is more expensive than the extrusion process due to the cost of the tooling and the higher precision required by the process. The extrusion process is relatively inexpensive and can be used to manufacture heat sinks in large quantities.

 4. Heat dissipation

Heat dissipation is a key factor to consider when selecting a heat sink. Normally die cast heat sinks have lower thermal conductivity than extruded heat sinks due to the use of material .For example, extrusion heat sink often uses AL6063 (with thermal conductivity of 200W/mK) while die cast heat sinks often use ADC12 (with thermal conductivity of around 96W/mK). but in order to improve the thermal conductivity of die cast heat sink , we often choose Aluminum alloy materials that balance hardness and better heat dissipation performance than ADC12.

Die Cast Heat Sinks vs Extruded Heat Sinks - Which Is Better?

 When choosing between die-cast and extruded heat sinks, there is no clear answer as to which is better. The correct choice depends on several factors, including heat sink design, cost, and thermal performance requirements. In general, die-cast heat sinks are better suited for applications that require complex shapes and designs . On the other hand, extruded heat sinks are better suited for applications that require simple shapes and cost-effective production.

Conclusion

 In conclusion, the choice between die cast heat sinks and extruded heat sinks will depend on the specific needs of the application. Each method has its advantages and disadvantages, and it is up to the engineer to decide which method is more suitable for the application. Die-cast heat sinks offer greater design flexibility , making them a better choice for complex applications. Extruded heat sinks, on the other hand, are more cost-effective and better suited for simpler applications. By considering all relevant factors, engineers can make an informed decision and select the proper heat sink for their application.