A 6063 base plate is machined with grooves on the pitch required, and straight aluminum fins are cut to the full height, inserted with thermal epoxy and cured under load. The base face is fly-cut after bonding for flatness, edges are deburred, and the part can be anodized black to raise emissivity in a sealed enclosure.
Height a die cannot pull.
Buoyant flow keeps moving in still air.
Mass goes into surface, not into base.
Radiative path in a sealed box.
No die, so pitch and height are free.
| Base Material | Aluminum 6063 base with tall bonded aluminum fins |
|---|---|
| Fin Height | 30-80 mm (higher on review) |
| Fin Thickness | 1.5-2.5 mm |
| Fin Gap | 4-10 mm for natural convection |
| Base Thickness | 4-10 mm |
| Base CNC Tolerance | Milling / drilling / tapping down to +/-0.005 mm |
| Dimensional Inspection | Hexagon CMM +/-0.001 mm; 2.5D optical projector |
| Quality System | ISO 9001:2015; IATF 16949:2016 |
| Capacity | 60,000+ thermal parts per year |
| Lead Time | Samples typically 7-15 days; production scheduled to volume |
Note: values above are KingKa build options and verified capability; final geometry, holes and finish are confirmed against your drawing.
A tall fin is only as good as its root: the bond has to carry the fin's own bending load during handling and vibration, so groove depth and cure pressure are set for stiffness, not only for thermal resistance.
Design & CFD. 3D layout with CFD review sizes the fin field, pipe route and base thickness to the load and airflow.
Base machining. Plate, pockets and pipe channels are milled on 50+ CNC centers to +/-0.005 mm.
Fin and pipe joining. Fins skived, stacked or extruded; pipes pressed and soldered; the stack joined to the base by the process the design calls for.
Face fly-cutting. Contact face machined flat after joining so the part sits true on the device.
Final inspection. Hexagon CMM (+/-0.001 mm) and 2.5D projector check critical features; 4-stage IQC / IPQC / FQC.
Fin pitch and height - measured against the drawing before packing.
Base flatness - fly-cut face checked on the contact side.
CMM report - critical dimensions to +/-0.001 mm.
Joint inspection - solder or weld fillet checked along the stack feet.
Visual and batch audit - IQC / IPQC / FQC on every run.
Tall bonded stacks are chosen when there is no fan to rely on:
Fanless outdoor cabinets
EV charging power stages
Rail and traction electronics
Power supplies in sealed enclosures
Telecom remote units
Send the orientation the sink will sit in, the ambient, the load and the height allowed. KingKa sets fin gap for the buoyant flow in that orientation, then bonds to the height the enclosure gives.
KingKa is a direct manufacturer with 16+ years in thermal production, 50+ CNC centers, in-house skiving, FSW and vacuum brazing, certified to ISO 9001:2015 and IATF 16949:2016.
Tell us the mounting orientation first - a tall stack that works upright can stall on its side, and the fin gap has to be chosen for the direction the heat actually rises.
One supplier for the whole assembly. Base, fins, pipes and hardware under one quality system.
CFD before tooling. Design review catches a bad layout before metal is cut.
Prototype to volume. Samples in 7-15 days, production scheduled to forecast.
