Project Overview
Complex CNC milled aluminum heat sink with optimized fin geometry. Designed for high-power LED applications where efficient heat dissipation is critical for component longevity.
Challenge
The design featured very thin and tall fins (aspect ratio 15:1), which are prone to vibration and chatter during machining. Maintaining the straightness of these fins was difficult.
Our Solution
We designed a custom vacuum fixture to hold the base firmly without distortion. We used high-helix end mills to evacuate chips quickly and reduce cutting forces, preventing the fins from bending during the cut.
Results
•Thermal performance improved by 20%
•No fin deformation or chatter marks
•Uniform anodizing finish
•Cost-effective production for volume order
