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Products / Extrusions / Extrusion Profiles


Aavid Thermalloy Heat Sink Extrusion ProfilesCreating Custom Profiles

Aavid Thermalloy offers 42 different base profiles to which fins with heights from 25mm to 140mm (1.0 inch to 5.5 inches) can be attached. Performance datasheets can be generated for any combination of base profile, fin height, and length.


Designing with Aavid Thermalloy
Using an existing extrusion shortens lead-time and minimizes tooling costs, but there are situations where a new extrusion design is necessary. Aavid Thermalloy engineers are available to provide assistance with the design of custom extrusions uniquely suited to your application.


Cost Saving Suggestions
The following helpful hints will facilitate the extruding process to minimize problems, such as die breakage and extrusion tolerances, and to incorporate labor-saving features into the profile.
  • Locate holes to fall between fins so burrs and shavings are kept to a minimum.
  • For higher volume applications (500 pieces or higher lot sizes with 2500 pieces or higher EAU), design hole and fin locations so that the part can be punched and does not need to be drilled:
    • Material thickness: 0.250 in [6.35 mm] maximum
    • Hole diameter > material thickness
    • Edge of hole should be minimum of 1½ times hole diameter from edge of part and/or 0.020 in [0.5 mm] minimum from base of nearest fin
Serrated Fins Increase Surface Area Fin Height to Spacing Ratio Avoid Small Masses Surrounded by Larger
Consider fin serrations for extra surface area Use a fin height to spacing ratio less than 6:1 (y/x) for ease of extrusion Avoid larger masses surrounding smaller ones (extrusions won't fill)
Extruded Rails for Clips Heat Sink (Fins with and without radius)
Use an extruded rail for mounting clips to save assembly costs Consider a radius on fins and bases for easier extrusion
60% Opening for Screw Bosses Extruded Slots
Use a 60% opening for screw bosses to improve extrudability Use serrated extruded slots for threaded hardware and straight slots for PC boards to save machining
Extrusion Interlocking Feature Clearance for Hardware
Use an interlocking feature to join two extrusions Design the extrusion with clearances to allow for
tools and hardware






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