Cold Forged Aluminum Heat Sink Design Guide: Material, Fin Geometry & DFM Designing a cold forged aluminum heat sink requires careful control of material grade, fin geometry, fin pitch, base flatness, and manufacturing constraints before tooling begins. The right design can deliver thin, high-density fins, efficient heat transfer, and reliable one-piece construction, while poor design choices can increase tooling costs or prevent the heat sink from meeting its thermal target. This guide covers aluminum grade selection, straight and shaped fin options, fin height and pitch, base contact requirements, and key DFM rules for cold forging. It also explains when cold forging offers advantages over extrusion and outlines the typical process from initial drawing and thermal analysis through tooling, validation, and mass production.
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