Non-Standard Round Heat Sinks-Custom Aluminum Cooling For Any Application

You have a round enclosure. A cylindrical housing. A motor that runs hot in a confined space. The off‑the‑shelf heat sinks on the market are either the wrong diameter, the wrong fin height, or simply not designed to fit the way you need.

 

That is where we come in.

 

We make non-standard round heat sinks. Whatever diameter you need. Whatever fin configuration your thermal load demands. One piece, extruded and machined to your drawing, with no "we cannot do that" conversations.

 

 

A round heat sink is exactly what it sounds like: a circular aluminum profile with a solid center and fins radiating outward or running parallel around the circumference. The shape itself is not new. What is harder to find is a supplier willing to build them in non‑stock sizes, with custom fin spacing, and with the mounting features your product actually needs.

 

 

We build round heat sinks from 6063‑T5 aluminum. Extruded first, then CNC machined, then finished to your specification. The result is a heat sink that drops into your round housing and works without compromise.

 

 

 

 

Round heat sinks work differently than linear extrusions. Here is why that matters for your product.

 

1. 360° Airflow

Linear heat sinks dump heat in two directions. Round heat sinks radiate heat in all directions. If your enclosure is round, or if natural convection is your only cooling option, a round profile simply performs better. Air rises through the center and pulls cooler air in from the sides. That chimney effect is built into the geometry.

 

2. Uniform Heat Spreading

Heat comes from the center - from an LED array, a power module, a motor housing. A round heat sink pulls that heat outward evenly, not toward one edge. No hot spots. No uneven thermal stress on your components.

 

3. Fits Round Enclosures

This sounds obvious, but it matters more than people think. If your product has a round housing, a round heat sink fits without wasted space. No awkward gaps. No extra brackets. Just a clean, efficient thermal interface.

 

 

We ship non‑standard round heat sinks to customers building:

High‑Power LED Lighting – Street lights, stadium lights, high‑bay fixtures, grow lights, architectural floods. Round COB LEDs pair naturally with round heat sinks. 

Power Supplies & Drivers – Circular power supply units for LED drivers, industrial converters, and battery chargers. 

Motor Controllers & Servo Drives – Round housings need round cooling solutions. We match the diameter and add mounting features specific to your drive.

IGBT Modules & Rectifiers – High‑power switching devices generate concentrated heat. A round, radial fin design spreads that heat efficiently.

Telecom & RF Equipment – Base stations, amplifiers, and transmitters often use cylindrical enclosures. Round heat sinks integrate cleanly. 

Industrial Automation – Sensors, cameras, and controllers that run warm in compact, circular housings.

 

If your device generates heat and lives inside a round or cylindrical housing, we have a solution.

 

 

We control the entire process. No handoffs. No surprises.

 

Step 1 – Drawing Review

You send your drawing - STEP, IGES, DXF, DWG, PDF, or even a sketch. Our engineers review the geometry, the tolerances, and the material requirements. If something will be difficult to extrude or expensive to machine, we tell you before you commit to tooling.

 

Step 2 – Custom Die Design & Fabrication

We design and build the extrusion die in‑house. Round profiles require careful die design to ensure even material flow and consistent fin geometry around the entire circumference. We have done enough of them to get it right the first time. Die lead time: 4–6 weeks.

 

Step 3 – Aluminum Extrusion

6063‑T5 billet goes into the press. The profile comes out the other end - round, straight, and dimensionally consistent. We stretch it to relieve internal stress and cut it to rough length.

 

Step 4 – CNC Machining

This is where a raw extrusion becomes your finished part. We machine mounting holes, threads, counterbores, slots, or whatever your drawing specifies. We also cut the final length, machine the center hub if needed, and ensure flatness on the mounting surface. CNC tolerance down to ±0.01mm on critical features.

 

Step 5 – Surface Finishing

- Anodizing(clear, black, or custom colors) – adds corrosion resistance, looks clean, does not interfere with thermal performance.

- Powder coating (any RAL color) – durable finish for harsh environments.

- Sandblasting – uniform matte texture.

 

Step 6 – Quality Inspection

Dimensional check. Visual inspection. CMM for tight tolerances. Every part is verified before it leaves the shop.

 

Step 7 – Packaging & Shipment

Foam, cartons, wooden crates - whatever it takes to get your parts to your dock without damage.

 

 

We Actually Build Non‑Standard Sizes

Most heat sink suppliers have a catalog. If your diameter is not in that catalog, they say no. We say yes. We build round heat sinks in whatever diameter you need, from 30mm up to 320mm. No stock constraints. No "we only do these three sizes."

 

 

We Handle the Hard Geometry

Round heat sinks are not simple extrusions. The fin density varies around the circumference. The material flow must be balanced. We have the die‑making experience and extrusion expertise to get it right.

 

One Roof, No Middlemen

Die design, extrusion, CNC machining, finishing - all in‑house. That means one point of contact, one quality standard, and no finger‑pointing if something goes wrong.

 

We Tell You the Truth

If your fin height is too tall for the diameter, we tell you. If a tolerance is tighter than it needs to be, we suggest a looser one. If a different alloy would work better, we recommend it. No surprises. No wasted tooling spend.

 

We Ship Everywhere

Daily. To North America, Europe, Southeast Asia, Australia. We know the paperwork, the packaging, and the logistics.

 

 

 

 

Q: What is the smallest and largest diameter you can make?

A: We regularly produce round heat sinks from 30mm up to 320mm in outer diameter. Larger diameters are possible depending on extrusion press availability. Contact us with your requirement.

 

Q: How thin can the fins be?

A: Down to 1.0mm for high‑density designs. Fin height and thickness must be balanced - our engineers will advise you based on your diameter and thermal load.

 

Q: What is the lead time for a custom die?

A: Typically 4–6 weeks for die design and fabrication. Samples available 1–2 weeks after die completion.

 

Q: What is the minimum order quantity?

A: Depends on diameter and profile complexity. Small runs are doable. Large runs are economical. Ask us.

 

Q: Can you machine mounting holes on the bottom of the round base?

A: Yes. We can drill, tap, counterbore, or machine slots on the mounting surface. Just show us the location on your drawing.

 

Q: What file formats do you accept?

A: STEP, IGES, DXF, DWG, PDF. Or send a physical sample and we will reverse engineer it.

 

Get a Quote

You have a round enclosure and a thermal problem to solve. Send us your drawing - even a rough sketch with dimensions. Tell us your target power dissipation, your available airflow, and your mounting constraints. We will get back to you with a quote and a timeline you can actually plan around.

 

Email: general@zp-aluminum.com

Web: www.zpheatsink.com

Location: Foshan, Guangdong, China

 

 

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