Custom Heat Sink Solutions

Celsia is a U.S. corporation specializing in custom heat sink solutions using two-phase technology: heat pipes, vapor chambers, thermosiphons, and phase change materials. Our design, prototyping, and production facilities, along with our quality and high-availability engineering sales departments, are structured to meet the demands of custom small-to-mid-volume heat sink orders. We prioritize fast response times, SWaP-C design optimization, and benchmark-quality systems.

Significant 2-Phase Experience

If your application demands deep expertise, partnering with a specialized innovator offers key advantages. We application-tune each heat pipe and heat sink design while engineering solutions for efficient, scalable manufacturing.

Thousands of 2-Phase Thermal Solutions Completed

With thousands of successfully developed two-phase thermal solutions, we apply data-driven precision to every new project. Our engineering-driven approach includes:

• Excel based thermal modeling & CFD simulation to optimize design criteria before prototyping.
• Extensive prototyping & iterative design refinements to meet unique cooling challenges.
• Real-world testing & validation to ensure thermal efficiency and durability.

97% of Our Custom Heat Sinks Are Two-Phase Designs

Our expertise is deeply rooted in two-phase cooling solutions, where nearly all our heat sink designs incorporate heat pipes, vapor chambers, or other two-phase technologies. This focus reflects our commitment to innovation in advanced two-phase thermal management, ensuring optimal heat dissipation, high reliability, and long service life for mission-critical applications.

• Two-phase design, proto, and manufacturing are an everyday occurrence for the Celsia team.
• Every optimization choice is backed by decades of two-phase heat sink experience.
• Fully customizable two-phase devices: material, wick (thickness, porosity), fluid loading, shape.

30+ Issued & Active Patents

Our patent portfolio and focused R&D work demonstrate leadership in two-phase cooling and related thermal management technology. These innovations include:

• Low-cost, one-piece vapor chambers for improved manufacturability.
• Self adjusting two-phase devices that accommodate variations in PCB and component stack height.
• Machined vapor blocks that efficiently transfer heat from multiple sources to a single condenser.
• Proprietary mounting techniques that enhance structural integrity and thermal conductivity.

Collaborative Design Philosophy

At Celsia, we prioritize customer collaboration to drive effective product design. By engaging early in the development process, we ensure optimal thermal performance, streamlined manufacturability, and seamless system integration—delivering solutions that meet engineering and production requirements.

High Availability of Engineering Resources

Collaboration is at the core of our design philosophy. Our flexible engineering schedules allow for short-notice design consultations, video conferences, and data clarifications, ensuring seamless communication and efficient problem-solving. By being readily available, we:

• Provide readily available engineering support to accelerate design iterations.
• Enable rapid design adjustments based on performance simulations.
• Ensure continuous alignment with customer requirements throughout the development process.

Application Requirements Definition & SWaP-C Priorities

Understanding Size, Weight, Power, and Cost (SWaP-C) priorities and trade-offs are critical to developing thermal solutions that are properly optimized for each application. Our approach includes:

• Collaborative requirement gathering to define thermal, mechanical, and integration constraints fully.
• Tradeoff analysis to balance cooling performance, manufacturability, and cost.
• Decades of two-phase optimization experience ensures the best possible heat sink performance within size, weight, and power constraints.

 

Full Support for Celsia or Customer-Driven CFD Modeling

Computational Fluid Dynamics (CFD) modeling plays a critical role in heat sink/thermal solutions design. Whether using our in-house simulation expertise or working with customer-provided models, we:

• Validate thermal performance early in the design cycle.
• Identify and resolve potential issues before manufacturing.
• Provide data-backed design recommendations to optimize performance and manufacturability.

Benchmark Quality Systems

Celsia’s commitment to industry-leading quality standards ensures that every two-phase heat sink solution meets the highest levels of performance, reliability, and longevity.

Since two-phase devices are the most critical component of a heat sink, we control every aspect of their production to ensure stand-alone devices and completed thermal assemblies are ready for mission-critical and long service life applications.

Raw Material Control

Beyond precision manufacturing, the durability of two-phase devices depends on the quality of raw materials. To ensure long-term performance and prevent brittleness, leakage, or outgassing, we maintain strict material control:

• Copper tubing & sheets: Independently batch tested by Celsia to validate claimed purity and oxygen content.
• Powdered Metal: Batch-tested for purity; sintering material is sorted and graded by particle size and distribution.
• Working Fluid: In-house water filtering and deionization, while alcohol is double distilled and stored in a controlled environment.

First Article Validation

Before full-scale production, we verify that every newly developed part meets the required specification. This ensures compliance with customer and regulatory standards, prevents costly defects, and establishes a baseline for future production.

While validation is tailored to each application, including MIL-STD-810 testing—our baseline tests apply to both stand-alone two-phase devices and completed thermal assemblies.

Mass Production

During mass production, 100% of two-phase devices undergo rigorous testing, including:

• 48-hour burn-in period to detect contaminants.
• High-pressure helium leak check for structural integrity.
• Performance validation of Qmax and thermal resistance (ΔT).
• Dimensional measurements to ensure precise specifications.
• Cosmetic validation per custom specification.

All completed thermal assemblies undergo 100% testing to meet performance, dimensional, and cosmetic standards. Further, Celsia is ISO certified and compliant with ITAR, MIL 810, RoHS, and REACH standards.

Agile Organizational Structure

Businesses that excel in custom, low-to-mid volume production are built to manage a variety of highly customized and technically advanced projects. Our operations are designed around cross-functional collaboration, flexibility, and iterative development to ensure efficiency and precision.

Integrated, Cross-Functional Approach

• Engineering, production, and quality control (QC) teams work in parallel to align design intent, manufacturability, and performance from the outset.
• This cohesive structure minimizes delays and enhances design efficiency, reducing the need for late-stage revisions.

Agile & Scalable Manufacturing

• Enables rapid design modifications and material adjustments to meet specific application demands.
• Streamlined validation processes ensure performance requirements are met before full-scale production.
• Easily adapts to evolving customer needs and technical challenges, delivering optimized thermal solutions.

At Celsia, our deep expertise in two-phase thermal management, commitment to quality, and customer-centric approach make us a trusted partner for advanced cooling solutions. From early-stage design collaboration to rigorous manufacturing and validation, our integrated approach ensures that every heat sink and thermal assembly meets the highest standards of performance, reliability, and durability.

Contact us today to discuss how our two-phase thermal expertise can enhance your next project.