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Views: 0 Author: Site Editor Publish Time: 2026-08-25 Origin: Site
Pin fin cold forged heatsinks move air in every direction, which makes them a strong fit for LED, power supply, and inverter cooling where airflow is uneven.
This article shows where they work best and how to size them for your application.
Table of Contents
Pin fin and splayed pin fin heat sinks are a sweet spot for cold forging. They cool well in small, enclosed devices where airflow is uneven or comes from more than one side — exactly the conditions inside LED drivers, power supplies, and inverters.
This article explains why cold forged pin fins fit these applications, how to size them, and what to specify to your supplier. For the full process background, see our cold forged heat sink complete guide.
Straight parallel fins only use air flowing along one axis. Pin and splayed fins present surface from many directions, so they capture air that enters from the side, the top, or through a small vent. In a sealed driver or inverter, that multi-directional capture is what keeps the part cool. The what is a pin fin heat sink page explains the airflow physics in detail.
High-brightness COB and stage LEDs run hot and fail early if overheated. Cold forged pin fins spread heat from the LED array across many thin fins, holding junction temperature down and extending life. Round or splayed pin fins also match round COB modules better than rectangular extruded sinks. For custom shapes, our custom aluminum heat sink manufacturer page covers prototyping.
Enclosed power supplies have little room and often only a small vent. Pin fins use that limited airflow from every direction, so the supply stays within spec under load. Cold forging also gives a one-piece, joint-free part that resists vibration in field units.
Inverters switch hard and run hot. A cold forged pin fin sink gives the density to hold temperature in a compact enclosure, and the one-piece base keeps thermal contact stable under thermal cycling. For material choice, see the cold forged aluminum design guide.
Fix the power — know the watts to dissipate and the max case temperature.
Fix the envelope — height and width limit fin length and pitch.
Match airflow — natural convection needs wider pitch; forced air allows denser fins.
Pick the grade — AL1070 for best conductivity, AL6063/6061 for strength and cost.
Confirm finish — anodizing for corrosion and look; see the anodized aluminum guide.
Extrusion cannot make true pin or splayed fins. If your application needs shaped fins for multi-directional airflow, cold forging is the process; extrusion only serves straight-fin needs. Our cold forging vs extrusion comparison shows the trade-offs.
Tip | Why it matters |
Set fin pitch to airflow | Too tight blocks air; too open loses surface |
Keep base flat | Lowers contact resistance to the chip |
Use shared base shape | Cuts tooling cost across variants |
Add fixings in drawing | Threads and clips should be designed, not added later |
Cold forged pin fin heat sinks are the practical choice for LED, power supply, and inverter cooling where space is tight and airflow is messy. They capture air from many directions, stay one-piece and strong, and beat extrusion on fin shape. Size by power, envelope, and airflow, pick the aluminum grade by conductivity vs cost, and confirm finish before production.
Send us your watts, envelope, and airflow and we will return a sized pin fin design with a thermal check.
Q1: Why not just use a bigger extruded sink?
If height is limited or airflow is multi-directional, a bigger straight-fin sink wastes space. Pin fins use it better.
Q2: Are pin fins good for natural convection?
Yes, with wider pitch. They present surface to rising air from all sides.
Q3: Can cold forging make round pin fins for COB LEDs?
Yes. Circular and splayed pin fins are a key strength of cold forging and match round light sources well.
Q4: Which aluminum grade for LED sinks?
AL1070 conducts best; AL6063/6061 are stronger and cheaper. Pick by conductivity need vs cost.
Q5: Do these sinks need a fan?
Not always. Many LED and driver units run passive. Add a fan only when power density is high.
Q6: How fast can you deliver a custom pin fin sink?
After the die is made, cycle times are short. Send specs for a lead-time estimate and free DFM review.
