Aluminum Die Cast Heat Sink Housings | LED, Power Electronics & EV | KastMfg
KastMfg produces precision aluminum die cast heat sink housings for LED lighting, power electronics, motor drives, and EV charging. Optimized fin geometry, 0.02 mm mounting face flatness, full surface finishing.
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Aluminum Die Cast Heat Sink Housings
Heat sink housings are the most thermally demanding die casting product family. The casting must simultaneously serve as structural enclosure, thermal conductor, and environmental seal. Fin geometry determines convection performance; base plate flatness determines conduction from the electronics; alloy determines the thermal path from junction to ambient.
KastMfg produces heat sink housings for LED lighting, power electronics, motor drives, and EV charging in A360 (113 W/m·K) and A413 (121 W/m·K) for applications where conductivity is the design constraint.
Types in This Family
| Type | Power Range | Cooling Mode | Alloy |
|---|---|---|---|
| LED streetlight housing | 50-100W | Natural convection | A360 |
| LED high-bay housing | 100-200W | Natural convection | A360 |
| VFD / servo drive housing | 0.5-5 kW | Forced air or natural | A380/A360 |
| Inverter housing (PV/EV) | 3-10 kW | Liquid or forced air | A360/A413 |
| EV charger EVSE housing | 7-12 kW AC | Natural convection | A360 |
| Power supply housing | 100-1,000W | Fan or natural | A380 |
Thermal Design Principles
Fin geometry for natural convection: Optimal fin spacing 5- mm, height-to-thickness ratio >=:1 (castability limit), fins oriented vertically for chimney effect. KastMfg validates fin geometry in thermal simulation before tooling.
LED board mounting face flatness: KastMfg face-mills all mounting surfaces to 0.01-0.02 mm flatness, confirmed by CMM. Air gaps from non-flat mounting surfaces are the highest thermal resistance point in the system.
Alloy Selection for Thermal Performance
| Alloy | Conductivity | Best Application |
|---|---|---|
| A380 | 96 W/m·K | Indoor electronics, cost-optimized |
| A360 | 113 W/m·K | Outdoor LED, coastal, premium drives |
| A413 | 121 W/m·K | Maximum performance, liquid cooling circuits |
IP Rating Capability
IP65 standard. IP67 on request (precision O-ring grooves, CMM verified, first-article pressure test). IP66 for high-pressure water jet environments (streetlights, tunnel lighting).
Applications
Municipal LED streetlights · Industrial LED high-bay and warehouse · Solar inverter and string inverter enclosures · EV AC charging stations · Industrial motor drive enclosures · Telecom outdoor equipment
Heat sink housing inquiry: yaoqingpu1983@gmail.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China
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