Custom Aluminum Extruded Heat Sinks — with CNC Machining & Heat Pipe Integration
BY Thermal manufactures custom extruded aluminum heat sinks from AL6063-T5 and AL6061-T6 profiles, upgraded with precision CNC machining or embedded copper heat pipes to handle high-power LED, IGBT, telecom, EV and industrial electronics.
What Is an Aluminum Extruded Heat Sink?
An aluminum extruded heat sink (also called an extrusion heat sink or extruded aluminum heat sink) is produced by heating aluminum billets to 520–540℃ and forcing the metal under high pressure through a precision die to create a continuous finned profile. It is one of the most cost-effective heat sink manufacturing methods, offering fast production, lightweight construction and easy customization for standard applications.
Extrusion alone covers many passive cooling jobs. When your design needs precision mounting features or higher heat flux, we add two upgrade paths — CNC machining and heat pipe integration — so you get the low cost of an extruded profile and the performance of a machined or two-phase thermal solution. See the extrusion process and the full extruded heatsink range for more detail.
Extrusion + CNC & Extrusion + Heat Pipe
Precision Extruded Heat Sinks, CNC Machined to Your Drawing
Extrusion gives you a low-cost, high-volume finned profile. CNC machining turns it into a ready-to-assemble part with precise mechanical features that extrusion alone cannot produce.
- Mounting holes, tapped holes, slots and counterbores held to tight tolerances
- Stepped bases, pockets and complex secondary geometry
- Typical machining tolerance of ±0.05 mm (confirmed per drawing)
- Cut-to-length, drilled, tapped, deburred and ready for assembly
Extruded Heat Sinks with Embedded Copper Heat Pipes
Plain aluminum is limited by its thermal conductivity. By embedding sealed copper heat pipes into the extruded base, heat moves quickly from a concentrated source across the whole fin array — without the cost of skiving or liquid cooling.
- Fast heat spreading from hot spots to the full fin field
- Compact, low-profile designs with a smaller fin footprint
- Round or flat heat pipes, custom layouts for your power map
- Cost-effective for medium-to-high power electronics
Featured Extruded Aluminum Heat Sinks
Extruded Heat Sink Capabilities & Specifications
| Parameter | BY Thermal Capability | Notes |
|---|---|---|
| Aluminum alloy | AL6063-T5 (standard), AL6061-T6, AL3003 | Selected by application & strength needs |
| Fin thickness | 0.5 – 3.0 mm | Standard extrusion range |
| Profile length | Custom cut-to-length profiles | Range depends on die & extrusion capacity |
| CNC machining | Milling, drilling, tapping, reaming, slotting | Typical tolerance ±0.05 mm |
| Heat pipe integration | Round / flat copper heat pipes in extruded base | Custom layout per power map |
| Surface treatment | Clear / black anodizing, sandblasting, powder coating, plating | Aesthetic & corrosion options |
| Assembly | Heat pipe soldering, hardware insertion, TIM application | In-house, single source |
| Prototype lead time | 15 – 25 days | From drawing approval |
| Compliance | RoHS-compliant materials | On request |
* Final alloys, tolerances, lead times and MOQ are confirmed during engineering review of your drawing.
Applications of Custom Extruded Aluminum Heat Sinks
LED Lighting
Street, industrial and horticultural lighting; anodized profiles prevent light decay.
Power Electronics & IGBT
Inverters, converters and servo drives that need high heat flux and reliable mounting.
Telecom & 5G
Base stations and RF equipment requiring compact, low-profile cooling.
Industrial Automation
PLC controllers, motor controllers and sensors in sealed enclosures.
New Energy Vehicles
Motor controllers, on-board chargers and battery thermal management.
Consumer Electronics
Ultra-thin-wall extrusion for gaming laptops, mini PCs and compact devices.
Medical Equipment
Precision-machined extruded heat sinks for lasers and diagnostic systems.
Data Center & Computing
Extruded profiles for server and storage cooling in constrained racks.
From Drawing to Production
Drawing & DFM Review
We review your drawing, check manufacturability and run thermal simulation at no cost.
Die Design & Extrusion
Profiles are extruded at 520–540℃ from AL6063-T5 or your specified alloy.
CNC Machining
Milling, drilling and tapping add the precise features your assembly needs.
Heat Pipe Integration
Copper heat pipes are embedded and soldered for two-phase heat spreading.
Surface Treatment & QC
Anodizing or coating, plus dimensional, visual and thermal inspection.
Packing & Delivery
Careful export packing with full documentation, delivered worldwide.
Why Buy Extruded Heat Sinks from BY Thermal
One-Stop In-House Manufacturing
Extrusion, CNC machining, heat pipe assembly, surface treatment and QC under one roof since 2016.
Engineering Support for Free
Thermal simulation, DFM review and cost optimization before you commit to tooling.
Fast, Reliable Prototypes
Typical prototype lead time of 15–25 days so you can validate before mass production.
Two Upgrade Paths in One Place
Choose extrusion + CNC, extrusion + heat pipe, or both — no need to juggle multiple suppliers.
OEM / ODM Flexibility
Built to your drawings, with your brand, packaging and export documentation.
Quality That Lasts
RoHS-compliant materials and rigorous dimensional, visual and thermal inspection.
Frequently Asked Questions
What is the difference between a skived heat sink and an extruded heat sink?
What aluminum alloys do you use for extruded heat sinks?
Can you CNC machine an extruded heat sink?
Can you add heat pipes to an extruded aluminum heat sink?
What is the lead time for a custom extruded heat sink prototype?
Do you offer surface treatment and assembly?
What is the minimum order quantity?
Get a Quote for Your Custom Extruded Heat Sink
Send your drawing or thermal requirements — our engineers will review feasibility, suggest the right combination of extrusion, CNC and heat pipe, and come back with a cost-optimized proposal.
Request a Quote Send Your Drawing