Custom Aluminum Heat Sinks For LED Modules--Built For Real Thermal Loads

Here is the thing about LED modules. They run hot. Not warm - hot. A single COB LED module can push 100W of power, and most of that ends up as heat. If you do not pull that heat out fast enough, the junction temperature climbs, the light output drops, and the lifespan gets cut short. We have seen it happen more times than we can count.

 

That is why we build custom heat sinks specifically for LED modules. Not generic extrusions that happen to fit. Heat sinks designed around your module, your power level, your mounting layout, and your airflow situation.

 

 

An LED module heat sink is exactly what it sounds like. A block of aluminum that sits under your LED module, pulls heat away from the chips, and spreads it into the air. Simple in concept. Less simple in execution.

 

 

The hard part is matching the heat sink to the module. A 50W module needs a different fin geometry than a 200W module. A module mounted vertically needs a different design than one mounted horizontally. A module in a sealed enclosure needs a completely different approach than one in open air.

 

We handle all of it. Extrusion. CNC machining. Surface finishing. You send us your module specs and your thermal requirements. We build the heat sink that fits.

 

 

 

 

Aluminum gets used for a reason. Not because it is the most conductive metal on the planet - copper wins that race. But because it hits the right balance for LED applications.

 

6063-T5 aluminum conducts heat at roughly 200 W/m·K. That is plenty for most LED modules. It is lightweight. A copper heat sink heavy enough to do the same job would add kilograms to your fixture. It extrudes cleanly into complex fin shapes. And it takes anodizing well, which protects the surface and improves radiative heat transfer in passive cooling setups.

 

For COB LED modules specifically, 6063 alloy holds the high tongue ratios and tight tolerances required for dense fin arrays.

 

 

1. Designed Around Your Module, Not Around a Catalog

We start with your LED module. Not our existing tooling. Not a standard profile we have sitting around. Your module dimensions, your power level, your mounting hole pattern. Everything else flows from there.

 

2. Flat Base Matters

The interface between your module and the heat sink is critical. If the base is not flat, you get air gaps. Air gaps mean thermal resistance. Thermal resistance means higher junction temperatures. We machine the base flat to ≤0.05mm, sometimes tighter if your application calls for it.

 

3. Fin Geometry Optimized for Your Airflow

Passive cooling needs tall, tightly spaced fins to maximize surface area. Forced cooling can use shorter fins with wider spacing. We adjust fin height, fin thickness, and fin pitch based on how much air is moving through your fixture. There is no one-size-fits-all answer.

 

4. No Thermal Interfaces Inside the Heat Sink

Extruded heat sinks are one solid piece. No joints. No bonded fins. No interfaces that can degrade over time or under vibration. The heat path is clean from the module to the fin tips.

 

5. Mounting Features Built In

We machine whatever mounting features you need. Threaded holes for the module screws. Counterbores for standoffs. Slots for adjustment. Pockets for drivers or lenses. You name it, we cut it.

 

 

We ship LED module heat sinks to customers building:

 

- LED Street Lights – Modules from 30W to 200W. Outdoor-rated. Thermal loads that do not quit.

- High-Bay and Warehouse Lighting – High ceilings. Long hours. Passive cooling preferred to keep fans out of the equation.

- Stadium and Flood Lights – High power, often multiple modules per fixture. Heat sinks need to handle concentrated loads without blocking the beam.

- Grow Lights – 24-hour cycles in warm environments. Junction temperature control is critical to keep diodes from degrading.

- Architectural Lighting – Tight spaces, limited airflow. Every millimeter of fin height matters.

- Automotive LED Modules – Vibration, heat cycling, compact envelopes. Heat sinks need to be robust and precisely fitted.

- Industrial Task Lighting – Machine tools, inspection stations, assembly lines. Often mounted in orientations that complicate natural convection.

 

 

If you are putting an LED module into a product and it runs hot, we have seen your problem before.

 

 

 

Step 1 – You Tell Us What You Need

Send us your LED module specifications. Power. Dimensions. Target junction temperature. Ambient temperature. Mounting constraints. Airflow situation. A drawing or CAD file if you have one. Even a sketch works.

 

Step 2 – We Design the Profile

Our engineers run the numbers. Required surface area. Fin density. Base thickness. We simulate the thermal performance before we cut any tooling.

 

Step 3 – Extrusion Die Fabrication

We build the die in-house. 4 to 6 weeks. The die determines everything - fin geometry, wall thickness, overall shape. We do not outsource this step.

 

Step 4 – Extrusion

6063-T5 billet goes into the press. The profile comes out. We stretch it to relieve internal stress. Cut to rough length. Age it to T5 temper.

 

Step 5 – CNC Machining

This is where the extrusion becomes a finished heat sink. We cut to exact length. Machine the base flat. Drill and tap mounting holes. Machine counterbores or pockets. Whatever your assembly needs.

 

Step 6 – Surface Finish

Anodizing is standard. Clear. Black. Custom colors. Anodizing protects the aluminum, improves emissivity for passive cooling, and gives the part a professional look. Black anodized surfaces actually radiate heat better than bare aluminum in natural convection environments.

 

Step 7 – Inspection

Dimensional check. Flatness verification. Visual inspection. If the tolerances are tight, we put it on the CMM.

 

Step 8 – Pack and Ship

Foam-lined cartons. Wooden crates for large orders. Shipped to your dock, wherever that is.

 

 

We Have Done This Before

Not just extrusion. Not just CNC. Not just anodizing. All of it, together, for customers who build LED modules into real products that ship in volume. We have learned what works and what does not.

 

We Build the Die Ourselves

Extrusion dies are the difference between a heat sink that works and one that fights you every step of the way. We design and fabricate our own dies in-house. That means faster turnaround, better quality control, and no finger-pointing when something needs adjustment.

 

We Tell You If Something Is Wrong

If your mounting holes are placed where they will hit a fin, we tell you. If your target junction temperature is unrealistic for the available space, we tell you. If a different fin geometry would perform better, we recommend it. No surprises. No wasted tooling.

 

One Roof, No Middlemen

Die design, extrusion, CNC, finishing - all in-house. You deal with one point of contact. You get one quality standard. You receive one shipment.

 

We Ship Everywhere

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

 

 

 

Q: What information do you need to quote an LED module heat sink?

A: Module power (watts). Module dimensions. Target junction or case temperature. Ambient temperature. Available space for the heat sink. Airflow conditions. A drawing or CAD file if you have one.

 

Q: Can you design a heat sink for a specific COB LED module?

A: Yes. That is most of what we do. Send us the module datasheet. We will size the heat sink accordingly.

 

Q: How flat can you machine the mounting surface?

A: Standard is ≤0.05mm across the mounting area. Tighter tolerances are possible on request.

 

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

A: 4 to 6 weeks for die design and fabrication. Samples available 1 to 2 weeks after that.

 

Q: What is the minimum order quantity?

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

 

Q: What file formats do you accept?

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

 

Q: Do you offer thermal simulation?

A: Yes. For qualified projects, we run CFD analysis to validate the design before we cut tooling.

 

Q: Why 6063 instead of 6061 for most LED applications?

A: 6063 has slightly better thermal conductivity (~200 vs ~180 W/m·K) and extrudes more easily into complex fin shapes. 6061 is stronger, but most LED heat sinks do not need that strength.

 

 

 

You have an LED module that runs hot. You have a target junction temperature you need to hit. You have space constraints and mounting requirements

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Send us the specs. We will design a heat sink that fits, cools, and survives. 

 

Email: general@zp-aluminum.com

Web: www.zpheatsink.com

Location: Foshan, Guangdong, China

 

ZP HEAT SINK, From Drawing To Reality.

 

 

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