The body and both ear flanges are cast in A380 in one shot, with the square port opening formed by a die block on the side. After casting the top face is fly-cut, the ear holes and the port screw holes are drilled, and the part is finished in a dark passivation rather than a coating - the housing is often used where the surface has to stay conductive for earthing. Other housings in the die casting heat sink range use the same conductive finish for the earth path. Where the cast ear stops and machining starts is the subject of die casting vs CNC machining.
No bracket between housing and panel.
Low profile with a full fin run.
Formed by a die block.
Positioned from the machined face.
Passivation keeps the surface earthed.
| Base Material | A380 aluminum, high-pressure die casting, dark passivation |
|---|---|
| Body | Flat housing, low profile |
| Mounting | Cast ears at both ends, holes drilled |
| Port | Square opening on one side |
| Fin Field | Dense straight fins on the top face |
| Finish | Dark passivation (conductive) |
| 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.
An ear that is cast too thin will not take the bolt torque, and one that is cast too thick will shrink-pull the top face out of flat. The ear thickness is set by the bolt, and the surrounding wall is then adjusted to feed it.
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.
Housings with cast ears are used where the unit mounts to a panel with no bracket:
RF modules
Radio and repeater units
Panel-mounted controllers
Power distribution units
Outdoor sensor housings
Send the panel cutout, the ear hole spacing, the port size and whether the surface must stay conductive. KingKa checks the ear thickness against the die rules and sets the hole positions relative to the machined face, so the part mounts flat instead of stressing the panel. When the electronics need fins on every wall rather than the top face, the four-side fin enclosure is the next step.
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.
Give the bolt size and the ear spacing. Ear thickness follows the fastener, and a drawing that gives only the outline leaves us to guess whether the ear can take the load.
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.
