Custom Heatsink

A Custom heatsink is a good choice for the for the most challenging applications. In the simplest form, Radian Thermal Products can use one of our wide range of standard heatsinks, and then modify to meet the thermal application requirements. Customizing a standard heatsink helps reduce a heatsink cost, and also can reduce the prototype time dramatically. For larger heatsinks, we can also look an existing extrusion before it has been cut for a standard heatsink. Where a standard heatsink can not be modified, our engineering team will then design a custom heatsink solution using the most appropriate manufacturing process.
Custom Heatsink

Custom Heatsink Design


When our Engineering team starts a design of a custom heatsink, it is very important that the customer has thought about a few factors such as:

  • Space Available for Heatsink: Width, Length, & Height
  • Power of the source in Watts, and size.
  • Air Speed in LFM & Direction of Air Flow
  • Maximum Operating Case or Junction Temperature
  • Local Ambient Temperature
  • Preferred attachment method
  • Thermal Interface Properties
  • Estimated Annual Usage & budget

With this information, Radian Thermal Products can then work with your team to select the best option for your thermal application.

Custom Heatsink Types

Custom machined heatsinks offer highly versatile machining capabilities, with low set-up costs, and are ideal for low to medium volumes. Radian provides high precision machined heatsinks with complex features, contours, cut-outs and through-holes. 

Custom Aluminum Extrusions have conventionally been the predominant approach for low cost heatsink production. 

Investment Casting

The Investment Casting process can cost-effectively produce complex heat sink designs in a short amount of time. Investment Casting is ideally suited for producing prototypes and short-to med-volume runs. 

Die-Cast Aluminum offers cost effective solutions for medium, to large volumes. Using proprietary technology to cast a high thermal conductivity Aluminum alloy with a thermal conductivity 0f ~160 W/m-k.

Custom Forged Heatsinks can be manufactured using special open die tooling and intense pressure to form thin-sectioned, high precision heatsinks. High aspect ratios can be achieved using Precision Forging.

Custom Skived Heatsinks  combine special cutting tools and a controlled shaving technique to produce heatsinks from a single block of material, such as copper or aluminum. The typical result is a thin-finned heatsink, with a dense population of uniformly shaped and distributed fins.

Custom Stamped Fin heatsinks are made from sheets of aluminum or copper, where the metal is stamped into a particular configuration based on the intended application. For maximum design flexibility, fins can be stamped into a broad range of geometries and thicknesses. Stamped Fin heatsinks are useful approach for medium to high volume production.

Custom Heatsink Examples

Machined Heatsink

In this example a machined heatsink was rapidly designed and manufactured. The customer also wanted to use corporate colors in the coating.

Custom stamped heatsink

In this example a standard heatsink was machined so that it became a custom part..

Machined Heatsink

In this example a copper heatsink was machined as a platefin then cross cuts were added.

Machined and extruded heatsink

In this example an extruded heatsink was machined so that it could fit an assembly. After the machining the part was anodized.

A high majority of Radian Thermal Products’ business is the design, development and manufacturing of custom heatsinks for OEM applications that include Thermal Anaysis.  The examples below are just a handful of recent custom heatsink design and development projects.

Copper Heat Pipe Heatsink Assembly For High Brighness LED Application

Copper Heat Pipe Heatsink Assembly For High Brighness LED Application

Our customer was designing a substantially large High Brightness LED Assembly needing to dissipate substantial amount of heat to increase brightness and extend the life of their lighting fixture.

Utilizing advanced thermal analysis techniques, we were able to develop a solution utilizing copper heat pipes embedded in the base of the heatsink to more effectively draw heat from the LEDs  and distribute throughout the heatsink fins.  The end result eliminates hot spots with even distribution of heat across all the plate fins.

Custom BGA Heatsink / Extended for Extra Cooling

Custom BGA Heatsink / Extended for Extra Cooling

Late in the design stages for a networking customer, the customer miscalculated the amount of heat they would need to dissipate.  Having already spun and stuffed their boards, the customer had designed their boards to use our standard BGA Heatsinks with EZ-Snap Mounting Clips. They now required additional heatsink fins, yet had no method available to mount a larger heatsink without re-spinning and re-stuffing all their boards.

To solve the customer’s dilemma, Radian quickly designed and manufactured an extended BGA Heatsink that provided the extra heatsink fins required, while still using the same EZ-Snap Mounting Clip.  This approach solved the problem, saving the customer the customer the extensive costs and time required to re-spin and stuff their boards. 

Radian provided the solution without NRE and at costs only slightly higher than the standard BGA Heatsinks, keeping the client on schedule and on budget for the release of their system.

custom copper vapor chamber with stamped fins

Custom Copper Vapor Chamber with stamped fins

Radian Thermal Products recently developed this custom copper vapor chamber to cool a 103 Watt BGA chip.  The Vapor chamber has a custom shape to fit the customer’s board design.  The Vapor chamber is embedded with stamped copper fins to dissipate the heat.  Threaded mounting inserts affix the solution with the ideal pressure to mate the solution to the BGA chip.

Double-Sided Copper Skived Heatsink

Double-Sided Copper Skived Heatsink

The application was for a high end-processor card that was to mechanically fit within a 2.5 inch hard-drive slot.  The minimal space allowed for minimal height and required the higher dissipation rate offer by copper and skived fins.  We mounted heatsinks on both the top and bottom of the board to maximize heat dissipation.

Copper Heatsink for a Laser Diode in Optical Communications

Copper Heatsink for a Laser Diode in Optical Communications

Laser diode operating characteristics and life time are greatly affected by the temperature of the semiconductor junction. This is particularly true for the high power laser diode used by Radian’s customer where several watts of waste heat had to be removed from the small semiconductor laser chip. The round shape of Radian’s copper heatsink was tailored to best fit the the laser for improved thermal contact with the heat sink.  The compact fin design provides optimal thermal dissipation. At ambient temperatures of 25°C, this passive device holds the laser under 50°C.

Copper Skived Heatsink with Blower for 1U Server

Copper Skived Heatsink with Blower for 1U Server

The customer had an absolute limit on theta_SA of 0.6 C/W and the power to cool being 50 W. Radian provided a heatsink / blower solution with a theta_SA of only 0.52 C/W consisting of a copper skived heatsink with customized mounting and attached blower with speed control.

Copper Vapor Chambers in a two-sided Stamped Copper Heatsink

Copper Vapor Chambers in a two-sided Stamped Copper Heatsink

The customer required an advanced cooling solution to support a servo motor drive application. Radian came up with an enclosure that sandwiches the servo motor with copper vapor chamber on each side.  Each copper vapor chamber is populated with stamped copper fins.  The vapor chamber provide the best method to draw heat from hot-spots on the servo motor and then evenly distribute the heat into the heatsink fins.

Diecast Heatsink with Copper Heat Pipe for Encoder Card

Diecast Heatsink with Copper Heat Pipe for Encoder Card

We transitioned customer from an Extruded Aluminum Heatsink with secondary cuts and drills to a DieCast Heatsink design for reduced costs in higher volumes. New part has a copper heatpipe embedded in the base to improve thermal performance. 

Copper or Aluminum
Custom Designs
Rapid Prototyping

"Let us drive your heat away!"