Custom Industrial Aluminum Profiles For LED Heat Sinks-Tooling + Extrusion + Machining
Either way, you need a heat sink profile that does not exist in any catalog. And you need someone who can take that idea, build the tooling, run the extrusion, and deliver parts that match your print.
- Product Introduction
You have a drawing. Maybe it is a rough sketch. Maybe it is a fully dimensioned CAD file. Either way, you need a heat sink profile that does not exist in any catalog. And you need someone who can take that idea, build the tooling, run the extrusion, and deliver parts that match your print.
That is what we do every day.
What We Offer
This is not a "we sell standard profiles" page. Standard profiles are fine for some people. If you are reading this, you probably need something different. Different fin height. Different base thickness. A specific mounting channel. A shape that fits an odd corner of your enclosure.
We build custom extrusion dies. We run the profiles. We machine them. We finish them. You send the drawing. We handle the rest.
Service scope:
- Custom die design and fabrication (your cross-section, your dimensions)
- Aluminum extrusion (6063, 6061, 6005, 6082)
- Post-extrusion stretching and straightening
- CNC machining (cutting, drilling, tapping, milling, slotting)
- Surface finishing (anodizing, powder coating, sandblasting)
- Packaging and export
No middlemen. No "we will have to outsource the machining." One shop, one quote, one delivery.
Technical Specifications
| Parameter | Our Capabilities |
| Material | 6063-T5, 6061-T6, 6005, 6082 (others on request) |
| Thermal Conductivity (6063) | ~200 W/m·K |
| Max Profile Size | Up to 320mm circumcircle diameter (CCD) |
| Min Wall Thickness | 0.8mm (depending on geometry) |
| Fin Thickness | Down to 1.0mm for high-density designs |
| Fin Height | Up to 120mm |
| Extrusion Tolerance | GB/T 5237, EN 755, or custom as specified |
| CNC Tolerance | ±0.05mm standard; ±0.01mm on critical features |
| Surface Finishes | Mill finish, anodize (clear/black/custom), powder coat (RAL), sandblast, chemical film |
| Die Lead Time | 4–6 weeks |
| Sample Lead Time | 1–2 weeks after die completion |
| Production Lead Time | 4–6 weeks after sample approval |
What Makes Our Service Different
1. We Build the Die, Not Just Run It
Some shops send your drawing to a third-party toolmaker. We design and fabricate our own extrusion dies in-house. That means faster turnaround, better quality control, and no communication gaps when something needs adjustment .
2. We Actually Read Your Drawing Before We Quote
We look at tolerances. We look at wall thicknesses. We look at features that might be difficult to extrude or machine. If we see a problem, we tell you before you spend money on tooling. Not after.
3. One Roof, No Handoffs
Extrusion comes out of our press. It goes straight to our CNC shop. Same building, same people, same quality checks. You are not paying for a middleman. You are not waiting for someone else's schedule .
4. We Do High-Density Fins Without Breaking Tools
Thin fins, tight spacing, tall profiles-these are hard to machine without bending or breaking. We have done enough of them to know the fixturing, the tool paths, and the feeds and speeds that work .
Application
These profiles end up in all kinds of industrial and commercial products:
- LED Lighting Fixtures – Street lights, high-bay lights, floodlights, grow lights, architectural lighting
- Power Electronics – IGBT cooling, rectifiers, power supplies, motor drives, frequency inverters
- Industrial Equipment – CNC controllers, welding machines, servo drives, battery chargers
- Telecommunications – 5G base stations, RF amplifiers, network switches
- Automotive & EV – Onboard chargers, DC-DC converters, battery thermal management
- Renewable Energy – Solar inverters, wind turbine controllers
If your device generates heat and needs a custom cooling solution, we have a profile for it.
Manufacturing Process
Step 1 – Drawing Review & DFM
You send the file. Our engineers review it for extrudability and machinability. We look for thin walls, sharp corners, uneven wall thicknesses-anything that could cause problems. Then we give you feedback. If the design works, we move forward. If it needs changes, we tell you what and why .
Step 2 – Die Design & Fabrication
We design the extrusion die using CAD/CAM, then cut it from high-grade tool steel. Heat treat, polish, finish. A good die makes good profiles. We do not cut corners here .
Step 3 – Aluminum Extrusion
6063 or 6061 billets go into the press. Heated. Pushed through the die. Profiles come out the other end. We cool them, stretch them to relieve internal stress, and cut them to rough length .
Step 4 – CNC Machining
This is where raw extrusion becomes your finished part. We cut to exact length. Drill mounting holes. Tap threads. Mill pockets or slots. Machine mounting surfaces flat. Whatever your drawing calls for .
Step 5 – Surface Finishing
- **Anodizing**: Clear, black, or custom colors. Adds corrosion resistance, looks clean, does not hurt thermal performance .
- **Powder coating**: Any RAL color. Durable finish for harsh environments .
- **Sandblasting**: Uniform matte texture .
- **Chemical film**: For applications requiring electrical conductivity .
Step 6 – Quality Inspection
We check dimensions. We check surface finish. We check thread depths and hole positions. CMM for tight tolerances. No guesswork.
Step 7 – Packaging & Shipment
Foam, cartons, wooden crates-whatever it takes to get your parts to your dock in one piece.
Why Work with ZP Heat Sink?
We Have Been Doing This for Years
Not months. Years. We have seen the designs that work and the ones that do not. We have learned what extruders can and cannot do. That experience saves you time and money .
We Are Not a Broke
We are not a middleman. We are not a trading company. We are a manufacturer. You deal directly with the people who make your parts .
We Tell You the Truth
If your design is going to be expensive to tool, 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.
We Ship Worldwide
Daily. To North America, Europe, Southeast Asia, Australia. We know the paperwork. We know the packaging requirements. We know the logistics.
Customization Options
| Features | What We Can Do |
| Profile Geometry | Any cross-section that fits within 320mm CCD |
| Fin Configuration | Parallel, radial (sunflower), asymmetric, multi-height |
| Mounting Features | Threaded holes, through-holes, slots, pockets, dovetails |
| Surface Finish | Anodize (clear/black/custom), powder coat (any RAL), sandblast |
| Marking | Laser etching, silk screening for logos or part numbers |
| Packaging | Standard cartons, custom foam, wooden crates for large orders |
FAQs-Frequently Asked Questions
Q: What information do you need to quote?
A: A drawing (STEP, IGES, DWG, PDF) or detailed sketch with dimensions, tolerances, material, quantity, and surface finish.
Q: What is the minimum order quantity?
A: Depends on profile size and complexity. We work with small runs and large runs. Contact us with your requirements.
Q: How long does a custom die take?
A: 4–6 weeks for design and fabrication .
Q: Can you match an existing profile?
A: Yes. Send a sample or detailed measurements. We can reverse engineer and build a die to match.
Q: What is the difference between 6063 and 6061?
A: 6063 extrudes easier and has slightly better thermal conductivity (~200 vs ~180 W/m·K). 6061 is stronger. We recommend 6063 for most heat sinks unless structural requirements call for 6061 .
Q: Do you offer thermal simulation?
A: Yes. For qualified projects, we run CFD analysis to validate the design before tooling.
Q: What file formats do you accept?
A: STEP, IGES, DXF, DWG, PDF. Or send a physical sample.
Get a Quote
You have a drawing. You need a custom extrusion die and machined heat sink profiles. Send us your files. Tell us your quantity and timeline. We will get back to you with a competitive quote and a realistic schedule.
Email: general@zp-aluminum.com
Web: www.zpheatsink.com
Location: Foshan, Guangdong, China
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