Die Cast Heat Sinks

Die casting allows for the production of heat sinks of virtually any size and shape – from minute components weighing a few grams installed on PCBs, customised cooled electronic housings to complex formed parts of several kilograms in weight. They are typically made from aluminium, zinc or magnesium, whereby aluminium is now the preferred material.

Die cast heat sinks made in aluminium

Aluminium die casts are light in weight. In contrast to other die cast materials, aluminium can resist extremely high operating temperatures. Their strength, flexural rigidity and resistance to corrosion guarantee excellent heat dissipation. Due to its excellent shielding properties and light weight, aluminium is the preferred material for electronic housings.

Design and machining service

CTX offers both application-specific heat sinks and electronic housing made from die cast alloys. We assist you with our know-how from the very start of your project. Our project specialists produce the necessary CAD data and 3D models of the heat sinks and submits design proposals for optimised machining within the shortest of time. Changes to the design can be made quickly as the need arises. In addition, the CTX project engineers ensure that all cast parts are machined and finished according to customer specifications. CTX uses deburring, barrel finishing, grinding, brushing, polishing, sand blasting, glass bead blasting as well as complete CNC-machining. To finish die cast surfaces, we use powder coating, wet coating and chromatising. On request, we label and/or colour-code the parts according to your specifications, using screen and dabber printing.

Please note: Despite the relatively high tool costs, die casting is a cost-efficient solution even for small-batch production.

Embedded inserts and surface finishes

Copper, graphite and other materials with a temperature coefficient of expansion that is below that of aluminium can be embedded directly into the cast part. This way, high-strength mechanical bonds without any interfacial gaps or pores can be achieved. The fins, soldering parts and recesses can be customised to suit the electronic components and heat sink fixtures.


Thin fins with high aspect ratio

HDDC heat sinks offer many advantages over die cast or extruded units. Their higher thermal conductivity and unrivalled versatility when it comes to fin configuration, thickness and geometry allow for unusual yet highly effective designs with pin-shaped, elliptic or radial cooling fins. These are features that cannot be produced with conventional extrusion or die casting. HDDC also makes it possible to produce light-weight electronic housings with cooling fins and very thin walls with many bespoke features.

Enhanced post forming processes

Due to their high density, HDDC heat sinks can be machined, brazed and welded to produce leak-tight complex assemblies. Wet surface finishing processes like anodising and electroplating can be done without electrolyte retention in surface porosity.


  • Uniform heat distribution: 3D fins and cooling pipes as well as improved geometric properties such as very small enclosure wall thickness, tight fin spacing, thin fins and reduced draft angles result in perfectly uniform heat distribution.
  • Large-series production: Similar to die casting, HDDC is only viable for large-series production, using prefabricated inserts made in copper, stainless steel or other metals for heat distribution. HDDC parts can also be equipped with threaded inserts for liquid and other fittings.
  • Perfectly tight: For perfectly tight liquid cold plates, we recommend AL 6XXX alloys, CAB and standard brazing.


We are looking forward to your inquiry

We assist you in identifying the die cast heat sink models and dimensions that best meet your specific requirements. To find out more, simply give us a call!

CTX Thermal Solutions GmbH
Lötscher Weg 104
D-41334 Nettetal

Telefon: +49 2153 7374-0
Telefax: +49 2153 7374-10

E-Mail: info(at)ctx.eu

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