Custom Heatsink Development

Celsia’s step-by-step custom heatsink development process delivers optimized thermal solutions from concept to mass production. As a trusted heatsink manufacturer, we work closely with customers to meet demanding thermal and mechanical requirements. Below is an overview of our process, including typical turnaround times for each step.

Step 1: Define Custom Heatsink Requirements

Timeframe: A few days to a week depending on the customer’s schedule.

The first step in designing an effective custom heat sink is collecting application-specific data. If some values are unknown, estimates are acceptable. We frequently schedule video calls to clarify design intent and address technical challenges early. Here are some of the information we collect:

1. Application Type
   • Examples: military land electronics, telecom infrastructure equipment, low-orbit satellites.
2. Heat Source (for each IC that needs to be cooled)
   • Power in watts (TDP).
   • Size (LxW).
   • Lidded or unlidded IC.
   • Max Tcase or Tjunction in °C.
   • Duty cycle (if applicable).
3. Operating Environment
   • Min/Max operating temperature (°C).
   • Min/Max storage temperature (°C).
   • Elevation range (above/below sea level).
   • Other environmental factors: high shock and vibe environments, heat, humidity, salt spray, etc.
4. Custom Heatsink Specifications
   • Natural or forced convection.
   • Airflow into heatsink (CFM or Velocity).
   • Available space for the heatsink (LxWxD).
   • Distance of heatsink relative to heat source (local or remote condenser).
   • Angle of orientation range (heat source location relative to condenser).
   • Rank order importance of size, weight, performance/power, and cost (SWaP-C).
   • If possible, provide STEP or other CAD files.

Step 2: Initial Custom Heatsink Thermal Modeling

Timeframe: A few days to a week per iteration; expect 2-4 iterations.

Celsia uses internal thermal simulation tools to model and compare multiple custom heat sink concepts. These models help us spot thermal bottlenecks and refine performance targets early in the design cycle.

1. Video Conference
   • Discuss results and assess feasibility.
   • Adjust SWAP-C priorities given known constraints.
2. Iterative Heatsink Refinement
   • Re-run thermal models, generate reports, and refine the custom heatsink design through ongoing customer collaboration.

Step 3: Heatsink CFD Development & Optimization

Timeframe: 1-2 weeks per iteration (minor tweaks faster). This step typically lasts 1-4 months, depending on the number of CFD iterations and customer response time to suggested changes.

As a custom heatsink manufacturer, we offer flexible CFD support:

1. Fully Turnkey: Celsia performs all CFD analysis, including fin geometry, air velocity, and surface temperatures.
2. Partial Support: We provide thermal design guidelines—such as material conductivity, fin dimensions, and pressure drop assumptions—for customer-executed simulations.
3. Scope and Pricing: CFD work focuses on the custom heatsink unless broader enclosure analysis is requested. Budgetary pricing is based on simulation complexity.

Step 4: Finalize Custom Heatsink Design for Prototype Build

Timeframe: 1-2 weeks if based on optimized STEP/CFD files.

While further refinement may follow prototype testing, this step includes heatsink drawings, specifications, and tolerances.

Step 5: Prototype – Tooling, Production, & Validation

This step involves soft tooling, production and testing jigs, prototype build, and Celsia testing of the thermal solution before being shipped to the customer.

Timeframe: 6-8 weeks, depending on the design.

Includes soft tooling, production fixtures, prototype build, and internal testing of the custom heatsink before shipment.

1. Thermal Evaluation: Thermal resistance and delta-T tests at room ambient are standard. If needed, we also conduct tests under customer-specified low- or high-ambient conditions.
2. Mechanical Testing: Includes dimensional inspection and optional shock/vibration testing based on industry or customer standards.

Step 6: Customer Prototype Testing, Design Refinements

Timeframe: Duration is entirely dependent on the customer’s schedule.

Customer installs the custom heat sink prototype into their system for operational testing. Feedback from this stage is used to finalize the design.

Step 7: Custom Heatsink Mass Production

Timeframe: 6-10 weeks, depending on the complexity and order volume.

Celsia’s heatsink manufacturing capabilities include hard tooling, fixture development, and stringent QC. Whether for high or low volume, each custom heatsink is produced with precision.

1. First Article Testing: As outlined in the “Quality System Overview” document.
2. Mass Production QC Testing: Every custom heat sink or thermal assembly undergoes thermal, mechanical, and cosmetic inspection. All two-phase components receive 100% functional testing unless otherwise specified.

Total Lead Time Guidance for Custom Heatsinks

Built-to-print custom heatsinks can be completed, including tooling, in as little as 4 months, while full development projects typically last 5-12 months.

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