The part is cast in A380 with a multi-cavity die that uses slides to form the side opening and the deeper compartments. Walls are kept to a uniform thickness and blended into the bosses with generous fillets, because a sudden section change is where shrinkage porosity appears. After casting, the boss tops and the fin tips are machined flat, holes are drilled, and the part ships as-cast with no coating. It joins the structural castings in the die casting heat sink range, which are all quoted from the section drawing before the die is cut. Which alloy to name on that drawing is compared in ADC12 vs A380 selection.
Structure and heat path in one casting.
Flat and parallel after machining.
Four to five fins on one outer wall.
No coating, bare casting finish.
Side opening formed without a second op.
| Base Material | A380 aluminum, high-pressure die casting, as-cast |
|---|---|
| Cavities | Multiple compartments divided by cast walls |
| Fin Field | 4-5 thick straight fins on one outer wall |
| Bosses | Cast, machined flat on top |
| Tooling | Multi-cavity die with slides |
| Finish | As-cast, no coating |
| 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 wall that carries load and feeds a boss at the same time has to be thick enough to act as a feed path, not just strong enough to hold. That is why the walls on this part are not as thin as a pure housing would allow.
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.
Structural castings are used where the part has to hold a load as well as move heat:
Industrial control units
Power conversion modules
Machine-mounted electronics
Transport and rail equipment
Heavy-duty sensor housings
Send the compartment layout, the wall thicknesses you need, the boss loads and the flatness callout on the mounting faces. KingKa checks the section transitions against the casting rules first, then sets the gate and overflow layout so the bosses are the last places to freeze. Where the base carries no internal walls, the thin die cast heat sink plate does the same job with less metal.
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.
Send the compartment drawing with the boss loads marked. Wall thickness is set by the feeding rule, and a drawing that only gives the outline cannot tell us whether the walls will shrink-feed the bosses.
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.
