Precision Heat Sink Machining | Custom Aluminum & Copper Solutions

Falcon CNC Swiss is a leading custom heatsink manufacturer and supplier specializing in high volume heat sink machining of precision thermal solutions. We manufacture high-performance custom aluminum heatsinks and custom copper heatsinks with complex fin designs for electronics, computing and automotive applications. Our heatsink manufacturing excellence addresses thermal management needs for your most challenging projects.

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Our Custom Heat Sink Fabrication Capabilities

We use advanced multi-axis CNC technology and tooling to address the challenges associated with custom heat sink fabrication:

Thin-Fin Machining: Accurate machining of fins of only 0.5 mm thick with aspect ratios as high as 15:1
High-Speed Production: Short cycle times due to optimized tool paths and machining techniques
Complex Geometries: Custom pin-fin, straight fin, and staggered fin designs
Surface Quality: Excellent surface finishes to optimize the thermal interface

Our CNC machined heatsinks provide superior thermal performance with perfect dimensional accuracy for your assembly requirement.

Our Custom Heat Sink Fabrication Capabilities

Our Advantage of Custom Heat Sink Manufacturing Solution

As leading custom heat sink manufacturer, we will make recommendations on all manufacturing processes; our CNC machined heat sinks offer the best performance for more demanding applications:

Material Properties: We offer 6061-T6 aluminum (167 W/mK) which is a substantially better thermal and mechanical property compared to die cast A380 (96 W/mK). We even offer copper C11000 (≥380 W/mK) for maximum performance.
Optimization of Precision: When it comes to fin thickness, we can achieve 0.5mm with 15:1 aspect ratios, which gives you more area for dissipating heat than die-cast aluminum or extrusion would ever allow.
Integrated Manufacturing: We can manufacture heatsinks with integrated mounting features and custom geometries in a single operation, removing the need for secondary manufacturing.
Speed and Flexibility: From prototype to high volume production in days, with no tooling costs, allows for faster design changes and market responsiveness.

If die casting or extrusion is preferred due to high volumes, we will manage the trusted manufacturing partners and we will still provide single-point quality control.

If you are looking for a process to guide your application, [contact us for a free design consultation] with our engineers.

High Performance of Custom Aluminum and Copper Heat sink

At Falcon CNC Swiss, we provide compressive thermal management solutions that fits your performance specifications, volume needs and budget considerations. Although our focus is on high-volume CNC machining of precision custom aluminum and copper heat sink, we realize that there are other manufacturing processes that might be more applicable within certain applications.

Here we have detailed the comparison of the manufacturing processes, choose your most value-added solutions at Falcon CNC Swiss:

Parameter	CNC Machined Heatsinks	Die Cast Heatsinks	Extruded Heatsinks
Process	Computer-controlled milling from solid billet	Molten metal forced into steel molds under high pressure	Heated aluminum forced through a shaped die to create continuous profiles
Materials	Custom aluminum heatsink 6061-T6, 6063-T5, 7075-T6 custom copper heatsink C11000 (≥99.9% Cu)	Aluminum A380, ADC12 Zinc Alloy ZA-8	Aluminum 6063-T5 (most common), 6061-T6
Thermal Performance	Excellent	Good	Very Good
Thermal Performance	No porosity, optimal density, precise fin geometry maximizes surface area	Some porosity may reduce effective conductivity	Consistent grain structure, good conductivity along extrusion direction
Design Flexibility	Highest	High	Limited
Design Flexibility	Unlimited complexity: any shape, thin fins, custom base heights, integrated features	Complex 3D shapes, logos, mounting features possible	Constant cross-section only, limited to die design capabilities
Surface Finish	Excellent	Good	Good
Surface Finish	Machine-finished surfaces ready for assembly or anodizing	May require secondary machining for critical surfaces	Generally good as-extruded, can be machined or anodized
Tooling Cost	None	High	Moderate
Tooling Cost	No custom tooling required, ideal for prototypes and design changes	Significant investment in steel molds required	Custom extrusion dies required, less expensive than casting molds
Production Volume	Prototype to High Volume	Very High Volume	Medium to High Volume
Production Volume	Ideal for high-volume heatsink production of complex designs	Only economical for very large runs (50,000+ units)	Cost-effective for long runs of standard profiles
Cost Structure	Higher per-part cost, no tooling investment	Very low per-part cost, high initial tooling investment	Low per-part cost, moderate tooling investment
Key Advantages	• Design freedom for optimal thermal performance	• Lowest cost per part at very high volumes	• Excellent cost-performance ratio
	• Rapid prototyping without tooling costs	• Complex 3D shapes in single operation	• Good thermal performance
	• Precision machining features and tight tolerances	• Good dimensional consistency	• Continuous length availability
	• Superior material properties with full density	• High production rates	• Consistent cross-section quality
Ideal Applications	• High-performance computing	• Consumer electronics	• LED lighting systems
	• Aerospace and defense systems	• Automotive components	• Power supplies
	• Telecommunications equipment	• LED lighting housings	• Industrial equipment
	• Medical devices	• High-volume commercial products	• Heat exchanger systems
	• Low-volume specialty applications		• Standard profile requirements

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Why Falcon Should Be Your Heatsink Supplier?

Thermal Engineering Expertise: We understand heat transfer principles and provide custom heatsink design optimization for optimal performance
High Volume Production: Automated manufacturing cells for high volume heatsink production with consistent quality
Full Manufacturing Services: Whether it be material selection, CAD, precision machining, die casting and extrusiton solutions, deburring, and finishing (such as anodizing for aluminum and passivation for copper)
Quality Assurance: Using statistical process control (SPC) we are able to ensure dimensional accuracy as well as consistency in thermal performance across production runs.
Design for Manufacturability: Our engineers offer free DFM analysis to optimize all aspects of your heatsink design for performance and cost-effectiveness.

As your aluminum heatsink suppliers, we can provide you with solutions that consider thermal performance, weight and cost to meet your application's requirements.

Ready To Optimize Your Thermal Management Solution? [Contact Our Thermal Engineering Team]

FAQ

Q: What is the minimum fin thickness that you can do for aluminum heatsinks?

A: We can routinely machine fin thickness down to 0.5mm, at aspect ratios up to 15:1 for aluminum heatsinks, thanks to our high-speed machining capabilities and tooling specialization.

Q: Can you do large volume orders for consumer electronics applications?

A: Absolutely, doing high volume heatsink production is the core of our business! Our automated manufacturing cells allow us to easily scale to production constraints of millions of units, while maintaining the same quality.

Q: Do you conduct a thermal performance testing or simulation?

A: Our focus is on precision and manufacturing, but we can provide you with a list of trusted partners that can perform thermal simulation and testing to validate your performance. We also provide material certifications and complete dimensional inspection reports.

Q: What are the available surface treatments of heatsinks?

A: For aluminum heatsinks, we offer anodizing (clear and colored) to improve corrosion resistance and surface hardness. For copper heatsinks, we provide passivation or other anti-tarnish treatment to defer oxidation.

Your Best Choice For Precision Machining Service

Welcome to Falcon Swiss Machining Factory, your premier source for high-precision manufacturing solutions.