Aluminium die-cast heat sinks and housings in complex geometries
Ideal for filigree as well as voluminous heat sinks in large quantities
Aluminium die casting is always a preferred process when the production of parts with complex geometries at comparatively low unit costs is required. These manufacturing features can be utilised specifically for the production of heat sinks for electronics. The advantages of die-cast aluminium lie in its lightness and comparatively high thermal conductivity. Die-cast aluminium heat sinks distribute heat efficiently and conduct it away from the component. The shapes that can be produced using aluminium die casting know almost no limits in terms of design and richness of detail.
Advantages of aluminium die-casting in heat sink production
- Complex geometries and fine structures possible
- Efficient heat dissipation via the aluminium material
- Cost efficiency with high quantities
- Lightweight zinc or aluminium die-cast parts with high temperature resistance
- Reliable cooling function of the dimensionally stable, rigid zinc/aluminium heat sinks
- Only minimal CNC post-processing required
- Various surface finishes possible
(anodising, chromating, painting, powder coating, etc.)
Increased performance of die-cast aluminium heat sinks through a combination of different techniques
Die-cast aluminium heat sinks are particularly effective due to their flexible design and their ability to distribute heat evenly over the entire heat sink. They are also lightweight and inexpensive to manufacture. These properties make them ideal for use in combination with other cooling technologies that improve heat dissipation and thus increase the overall cooling capacity for a component.
Aluminium die-cast heat sinks+ surface finishing
The various surface finishing options offer not only aesthetic enhancement through decorative colours and textures, but also considerable technical added value. The surface treatment reinforces the corrosion protection, which increases the durability and reliability of the heat sink under various environmental conditions.
Die-cast aluminium heat sink+ fan
Die-cast aluminium heat sinks, combined with fans, enable efficient heat dissipation. This results in higher cooling performance, even in environments with little or no convection. The flexibility to increase fin density and direct or integrate the airflow improves adaptability to specific cooling needs. In addition, directly integrated mounting points simplify installation and ensure seamless system integration. EKL offers a wide range of its own fan models as well as fans from well-known brands such as ebm-papst, SANYO DENKI, ADDA, JAMICON, STK and Everflow.
Aluminium die-cast heat sink+ heatpipe
The faster heat spread through heat pipes distributes the heat efficiently across the die-cast heat sink, which enables even heat distribution. This helps to avoid hotspots and transport the heat to more distant locations - such as the housing - which is particularly important in compact systems. In addition, heat pipes enable weight savings without compromising cooling performance.
Die-cast aluminium heat sink+ vapour chamber
The functional principle of the Vapor Chamber accelerates the heat spread, the heat is efficiently dissipated from the source to the die-cast aluminium heat sink. The heat sink ensures an even distribution of heat over a large surface area and avoids hotspots. The vapour chamber is also significantly lighter than a solid copper plate.
Let's talk about your cooling task!
Danny Weimer
Sales Department
+49 (0)7561 9837-28
d.weimer@ekl-ag.de
Make an appointment Enquiries by e-mail
Danny Weimer
Sales Department
+49 (0)7561 9837-28
d.weimer@ekl-ag.de
Make an appointment Enquiries by e-mail
Aluminium die-cast housing as heat sink for POI/HMI displays and more
The housing is often underestimated as a heat sink: die-cast aluminium is ideal for dual use in closed systems. The die-cast aluminium housing serves as a robust cover and at the same time as a passive heat sink. If die-cast aluminium is used as part of the housing, its surface, which is interspersed with cooling fins, ensures heat dissipation through convection. The waste heat from the electronic components is thus efficiently transported to the outside without wasting space. This enables efficient cooling in a very small space.
The integration of a mounting bracket into the die-cast aluminium housing is also easy to implement. This means that a die-cast aluminium heat sink is not only used to cool electronic components, but also as a robust motor housing or a stylish rear panel for a panel application such as POI / HMI displays, for example.
The integration of a mounting bracket into the die-cast aluminium housing is also easy to implement. This means that a die-cast aluminium heat sink is not only used to cool electronic components, but also as a robust motor housing or a stylish rear panel for a panel application such as POI / HMI displays, for example.
Cost-optimised and scalable in terms of mould and production volume
Die-cast aluminium heat sinks are widely used in the automotive, aerospace and electronics industries, in household appliances and lighting technology, in mechanical engineering and in the construction industry. They are an integral part of many devices and systems that require reliable heat dissipation to ensure optimised performance and component longevity.
Added value and extras
Our full service goes beyond the mere development, series production and logistics of your heat sinks. Do you need special bores or milling on your heat sinks? Do you want your heat sink to not only dissipate a lot of heat, but also look stylish? Would you like a product ready-to-plug-in with all accessories?
Welcome to EKL!
Welcome to EKL!
CNC machining
For prototypes, small series and customised reworking of heat sinks, we have modern 3- and 5-axis CNC milling machinesat our company headquarters. Complex machined and high-precision radiators are our speciality. Working areas of the machines:
Hermle C 400 (5-axis) 850 x 700 x 500 mm | Mikron VCE1000pro (3-axis) 1000 x 560 x 600 mm | Kondia B1050 (3-axis): 1000 x 500 x 600 mm
Hermle C 400 (5-axis) 850 x 700 x 500 mm | Mikron VCE1000pro (3-axis) 1000 x 560 x 600 mm | Kondia B1050 (3-axis): 1000 x 500 x 600 mm
Surface finishing
Our range includes various surface finishes to create a durable, corrosion-resistant surface. Nickel plating increases wear resistance and lustre. Chromating and passivation, especially with Surtec 650, provide additional protection against corrosion. Powder coating is another option for a robust and durable coloured surface. Painting and cathodic dip coating round off our wide range of surface colours and textures.
Attachments & accessories
Depending on the application, screws, springs or push pins ensure the secure and stable attachment of the heat sinks. Backplates provide additional stability and improved heat dissipation. Heat-conducting pastes and pads are naturally part of our range to enable optimum heat transfer between the heat sink and the heat source.
Secure packaging for transport
With a focus on perfect protection during transport, we develop packaging that not only fits perfectly but is also robust. Another important aspect of the range is the use of recyclable materials that contribute to sustainability and environmental friendliness.
EKL: Your aluminium die-cast manufacturer for heat sinks in electronic systems
Die-cast heat sinks are used in many applications due to their high precision and efficiency. The die-casting process enables the production of complex shapes with high dimensional accuracy and good surface quality, which makes die-cast aluminium heat sinks attractive for thermal management in many electronic systems. The manufacturing process allows large quantities to be produced quickly at favourable unit costs.
- 30 years of experience
- Engineering in Germany
- Full Service Heat Sink
- Cost-efficient development
- Fast market launch
- Maximum quality
The EKL project stages for your cooling solutionChoose your point of entry!
Our offer is as flexible as your needs. Are you still early in the development phase and want an idea generator for the best cooling solution? Do you have a ready-made device that gets too hot? Or are you simply looking for an alternative or additional supplier for a heat sink already used in series production? In EKL you will always find a flexible, agile and responsible partner for the cooling of your electronic components and complete systems, whatever the project phase. We look forward to your enquiry!
Counselling
Concept
Concept
In personal contact and open dialogue with you, our engineers create the creative space and framework to design the best cooling solution for your requirements from the wealth of options available.
Development
Feasibility / simulation
Feasibility / simulation
We test the idea for your heat sink virtually in the thermal simulation. Realistic computer simulations allow variations in manufacturing processes, system structures and other parameters.
Performance optimisation
Even a well-functioning heat sink can still be optimised. We determine the "how" and "how much" by simulating different materials or cooling technologies, for example, as well as simulating various environmental parameters.
Cost optimisation
An expensive heat sink can often be made significantly cheaper by using an alternative manufacturing process. Whether with the same or application-specific performance: we support your product development in reducing costs.
Production drawing
Prototype construction
Prototype construction
Prototypes from our design department enable early testing and targeted solutions to problems in your device. We create your functional and design prototypes with our in-house CNC production.
Series production
small to large
small to large
By manufacturing in-house and in Asia, we can offer all types of heat sinks from small to large series at competitive unit prices. We impress our long-standing customers with our consistently high quality.
Sampling
Incoming goods inspection
Incoming goods inspection
We make no compromises when it comes to quality: Development takes place in Germany and all series products are analysed by our German test laboratory according to test plans using state-of-the-art methods.
Surface finishing
Anodising, powder coating, painting etc. protect your heat sinks from corrosion and environmental influences. But colour is not just chic, because dark-coloured heat sinks also emit more radiant heat.
Assemblies
Pre-assembly
Pre-assembly
We actively relieve your production with pre-assembled assemblies. This reduces your workload per device and guarantees the highest quality, because as cooling professionals we ensure that the heat sink is optimally attached.
Quality assurance
Test plans
Test plans
We test according to our own and customer-specific test plans using the latest rapid thermal measuring equipment, 3D measuring machines, assembly tests and testing of various application scenarios.
Packaging design
Packaging production
Packaging production
EKL develops and produces customised packaging to optimally protect your sensitive heat sinks or assemblies in the sometimes harsh transport and storage environments.
Warehouse
& Logistics
& Logistics
With large storage capacities, we offer production-related stocking and consignment warehouses, just-in-time deliveries, customised delivery schedules and flexible shipping options for your individual requirements.
Direct comparison of the cast manufacturing processes
A filter is active, some data is hidden
| Extruded heat sinks | Cold forged heat sinks | Soldered heat sinks | Bonded cooling fins | Pressed cooling fins | Friction stir welding | Heatpipes | Vapour Chamber | Crimped heat sinks | Skived Fins | Die casting | Laserwelding | Vacuum brazing | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Thermal conductivity | |||||||||||||
| Heat dissipation over long distances | |||||||||||||
| Design freedom and flexibility in shape and size | |||||||||||||
| Low tool costs / initial investment | |||||||||||||
| Favourable unit prices | |||||||||||||
| Low set-up costs | |||||||||||||
| Economic efficiency for small series | |||||||||||||
| Economic efficiency for large series | |||||||||||||
| Can be combined with other technologies | |||||||||||||
| Surface finishing / resistance | |||||||||||||
| Heat transfer | |||||||||||||
| Standard products | |||||||||||||
| Material density | n.a. | n.a. | n.a. | n.a. | n.a. | n.a. | |||||||
| Space-saving, large surface area in a small space | |||||||||||||
| Weight-saving | |||||||||||||
| Position dependence / gravity dependence | |||||||||||||
| Machinability | |||||||||||||
| Mechanical stability | |||||||||||||
| Low wear and tear | |||||||||||||
| Homogeneity (material, no additional materials) | |||||||||||||
| Suitability for large coolers | |||||||||||||
| Suitability for small coolers |
• less suitable | ••••• excellently suited | n.a.: not applicable
Let's talk about your cooling task!
Frank Sichler
Sales Manager
+49 (0)7561 9837-47
f.sichler@ekl-ag.de
Make an appointment Enquiries by e-mail
Frank Sichler
Sales Manager
+49 (0)7561 9837-47
f.sichler@ekl-ag.de
Make an appointment Enquiries by e-mail