LED Die Casting Heat Sink
A large scale of LED heat sink are processed by die casting technology of which the advantages are low processing cost and high production capacity.
- Product Introduction
LED Die Casting Heat Sink
Complex Geometry Thermal Solutions for High-Volume Lighting
Overcome design limitations of extruded heatsinks with our precision LED Die Casting Heat Sinks – engineered for high-volume luminaires requiring complex geometries and integrated features. Utilizing high-pressure die casting (HPDC) technology, we produce near-net-shape thermal solutions with intricate cooling channels, mounting bosses, and aesthetic details impossible through extrusion. Our die-cast LED thermal management systems achieve superior thermal density through proprietary alloy formulations and optimized fin-wall designs, delivering 0.15-0.6°C/W thermal resistance while reducing assembly steps by 60% for commercial, automotive, and industrial lighting applications.
Product Description
What is die casting?
Aluminum die casting is the process of filling a mold with molten aluminum to create a product. With this process, incredibly complex aluminum parts can be produced and reproduced at scale.
Advantages of Die casting heat sink
Low processing cost , high production capacity. If the mold allows, it can produce heat sinks of various shapes.
Disadvantages of Die casting heat sink
The thermal conductivity of the cast zinc-aluminum alloy case of the lamp is about 96W/M.K, plus the auxiliary oxidation residue, and surface oil spraying or electroplating, etc., the actual thermal conductivity is even worse. If the aluminum alloy is used to cast the LED lamp case, the die-casting fins are very thick, which results in a small heat dissipation area with poor heat dissipation effect. Because the surface of the die-casting heat sink can only be sprayed or electroplated, it cannot be anodized. After a long time of use, the surface will peel off, which will affect the appearance. The material of die casting LED heat sink is usually made of ADC12. The cost of the mold is high, one mold is only suitable for one product, and the mold production cycle is long, usually 30-45 days.
Design Parameters
| Product | LED die casting heat sink |
| Material | Aluminum 6063-T5 |
| Process | Die casting, CNC machining, Surface treatment |
| Tolerance | 0.01mm |
| Dimension | Customized |
Die casting led heat sink
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Material: ADC12 Aluminum Alloy (Standard) / A380 (High Conductivity)
Thermal Conductivity: 96-140 W/m·K (Alloy Optimized)
Wall Thickness:
Base: 2.5-8.0mm
Fins: 1.2-3.0mm
Feature Capabilities:
Integrated screw bosses
Undercut cooling channels
Snap-fit components
EMI shielding compartments
Surface Finish:
As-cast (CT6)
Glass bead blasted
Black anodizing (Type II/III)
Dimensional Accuracy: CT6 per ASTM E505
Compliance: IATF 16949, RoHS, IP65-rated
Products Features
Geometric Freedom: Create complex die-cast cooling forms with 360° thermal management
Integrated Functionality: Combine heatsink, housing, and mounting in one unit
High-Volume Efficiency: 90-second cycle times for mass production
Enhanced Thermal Paths: Optimized fin-wall ratios for maximum convection
Corrosion Resistance: Salt-spray validated for outdoor luminaires
Vibration Damping: Denser grain structure absorbs 30% more shock than extrusions
EMI Management: Fully enclosed Faraday cage designs
Cosmetic Versatility: Class A surface finishes for consumer-grade products
Products Application
Our die-cast thermal solutions excel in demanding lighting environments:
Automotive Headlights & Taillights (SAE J2592 compliant)
Streetlight Optical Chambers
High-Bay Industrial Fixtures
Horticultural Grow Light Housings
Architectural Cove Lighting
Marine Navigation Lights
UV-C Disinfection Systems
Aviation Cabin Lighting
Die Casting Manufacturing Process
Die casting is the process where molten metal is injected into a mold under high pressure in the
Range of 10 - 210 Mpa. This will result in a highly uniform casting with very good surface finish and exceptional dimensional accuracy. Usually this can either eliminate or greatly reduce the machining required to finish the part.We can offer both the cold chamber process and the hot chamber process. In the cold chamber process the metal is ladled into the injection chamber for each shot. There is less exposure of the molten metal to the chamber walls and plunger. This is very useful for aluminum and copper alloys that would easily alloy with iron at elevated temperatures. The hot chamber process has the injection chamber which is connected to the die cavity permanently immersed in the molten metal. The hot chamber process is used for metals of low melting point and high fluidity such as tin and zinc.
The materials that ZP offers are alloys of aluminum, copper, zinc and magnesium. Zinc castings can be made with thinner wall thickness than aluminum due to high melt fluidity.
Maximizing productivity, minimizing rejections, minimizing secondary operations, and extending the life of tools is always our focus. With advanced CAD/Solid Works software, decades of experience, and a well-equipped tool room, our partner facilities can manufacture dies suitable for up to 1600-ton die casting machines.
To manufacture the highest-precision aluminum components, our partner facilities utilize 6 high-pressure cold chamber die casting machines ranging from 80 tons to 1600 tons in capacity. Secondary operations such as drill tapping, turning, and machining are performed in the tool shop. Parts can be powder coated, shot blasted, deburred, or sanded.
Supplying the highest quality die-cast parts is always our goal. Our ISO 9001:2015-certified manufacturing partner has well-established QC procedures, quality tools, worker training, and a focus on continuous improvement to accomplish this. Incoming materials are thoroughly tested and state-of-the-art measuring equipment is used to consistently produce high-quality parts.
ZP HEAT SINK - From Your Idea To Reality
With abundant comprehensive strength and high quality service, our products have been well sold all over the country and exported to many countries and regions including Italy, England, Germany, Burma, Thailand, Brazil, Argentina, Canada, America and Mexico.
ZP HEAT SINK sticks to the scientific development perspectives, and keep improving the energy conservation and emission reduction of the enterprises by intensifying comprehensive management and enhancing innovation to accelerate in becoming an eco-friendly modern enterprise.ZP HEAT SINK insists on the operation tenet of "unity and enterprising, exploring and innovation" to fully cooperate with customers, explore the career and create a wonderful future together.
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