Custom Heat Sink Design & Manufacture, End to End
As heat-dissipation needs grow, the heatsink decides whether a design runs cool or throttles. P&A International’s thermal engineers weigh the factors that drive performance — system airflow, orientation, attachment method, size, ambient conditions and budget — then design the heat sink, characterise its performance, prototype it and tool it for production on demand.
As an engineering-led contract manufacturer founded as an engineering consultancy, we assign one dedicated engineer to your project from thermal review to free off-tool samples, then scale into volume through our vetted partner-factory network, where every supplier is ISO 9000 certified or better.
consultancy + manufacture
per project, end-to-end
before mass production
every supplier certified or better
one-off to high volume
Heat sink technologies we deliver
Extruded heat sinks
Aluminium extrusion-based heat sinks — the low-cost, high-volume workhorse — with integrated heat pipes or liquid-cooling circuits, then machined, finished and assembled.
Heat-pipe assemblies
Copper heat pipes built into fin stacks and baseplates for spreading and moving heat. Pipes to 52 mm diameter and 820 mm length, up to ~500 W per unit, mesh / groove / sintered wicks.
Stamped & forged
Low-cost stamped heat sinks and dense forged pin-fin coolers for compact and LED thermal designs at volume.
Bonded, folded & skived fin
Tall, dense fins beyond extrusion limits — bonded and folded fin for large footprints, swaged and skived fin for maximum density from a single billet.
Engineering capability
- Thermal design — airflow, orientation, attachment, size, ambient and budget weighed together
- Performance characterisation and prototyping before tooling
- Extrusion, bonded, folded, swaged, skived, stamped and forged processes
- Heat-pipe integration — to 52 mm diameter, 820 mm length, ~500 W per unit; mesh / groove / sintered
- Liquid-cooling circuits integrated into the heat sink where required
- Machining — tapped holes, counterbores, flatness and parallelism
- Finishing — black / clear anodise, chromate, painting, masking
- Free off-tool samples with quality-assessment reports before any volume order
At a glance
| Processes | Extruded / bonded / folded / swaged / skived / stamped / forged |
| Heat pipes | To 52 mm dia, 820 mm length, ~500 W/unit; mesh / groove / sintered |
| Materials | 6063 & 6061 aluminium, copper bases & heat pipes |
| Cooling | Natural convection, forced air, heat-pipe & liquid-cooled |
| Integration | Embedded heat pipes, liquid circuits, fans, clips, brackets |
| Finishing | Anodise (black/clear), chromate, painting, masking |
| Samples | Free off-tool samples + quality-assessment reports before mass production |
| Quality | Every supplier in our network is ISO 9000 certified or better |
Why engineers & buyers choose PA
For design engineers
A true thermal-design partner — one dedicated engineer, performance characterisation, the full process range from extrusion to skived and forged, and heat-pipe or liquid integration where fins alone fall short. With thousands of designs in our library, a minor variation often already fits your thermal challenge.
For purchasing
Low-risk scalability — free off-tool samples before mass production, flexible MOQ from short runs to high volume, target-cost DFM, a single point of contact, and a vetted ISO 9000+ partner network managed end-to-end by P&A. Short runs and small quantities of customised parts are core to our business.
3 easy steps to get started
Send us your spec
Fill in the form and send your drawings or thermal requirement. One dedicated engineer replies promptly, asking for any drawings and technical specifications needed.
Review the quote
You promptly receive a quote for your custom heat sink, extrusion or heat-pipe assembly — review and comment on the technical aspects and pricing.
Place the order
On approval, our vetted China-based partner factories produce your heat sink. Free off-tool samples are sent before mass production, then the order is inspected, packaged and shipped.
Applications
LED lighting & drivers · power electronics & drives · telecom & data infrastructure · aviation & transportation · consumer goods · industrial & engineering products.
Heat sinks sit at the centre of our thermal and aluminium capability. Explore the aluminium design & fabrication hub, our custom heatsink product range, dedicated custom heat pipes, and custom aluminium extrusions for fin profiles.
How to order your custom heat sink
Drawings are reviewed in house by PA engineers and the proposed solution is focused on your specification and intended use. Off-tool samples follow once drawings are approved and tooling is made. A few early decisions shape the design:
| Process | Extrusion for cost and volume; bonded / folded / skived for fin density; stamped / forged for compact and LED coolers. |
| Heat pipes | Order pipes stand-alone or assembled into the heat sink; mesh, groove or sintered wick to suit orientation and power. |
| Natural vs forced | Natural convection needs more fin area and vertical fins; forced air allows denser fins — tell us the airflow. |
| Spreading | Large base, small hot source → add heat pipes or a liquid circuit to move heat across the fin field. |
| Volume | Short runs and small custom quantities are welcome alongside tooled, high-volume production. |
What to send us for a fast, accurate quote
The more of this you can share, the quicker we can return a proposed design and price:
- Power to dissipate (W), heat-source size and location
- Maximum component / case temperature and ambient range
- Airflow — natural convection or forced air (CFM)
- Mechanical envelope: height, footprint, fin direction, mounting
- Target cost and annual volume or call-off pattern
- Any drawing, reference design or physical sample
It’s likely we already have a design that, with minor modifications, suits your thermal challenge — send what you have and our engineer will take it from there.
📄 Download the heat sink technology selection & ordering guide (PDF)
Get a quote
Send your drawings or thermal requirement and one dedicated engineer will reply — typically within 48 hours — with a proposed heat sink design and indicative pricing. Short runs and small quantities welcome.
One dedicated engineer reviews every enquiry and replies with a proposed design and indicative pricing. Your details are used only to respond to your enquiry. Prefer email? support@pa-international.com.au