Aluminum Die Cast Heat Sink Housing Solutions
Aluminum die cast heat sink housings for LED lighting, power electronics, and EV chargers with optimized fin geometry, thermal alloys, and IP sealing.
Production Capabilities
Component examples for aluminum die cast heat sink housing
Component Range
Multiple die casting examples from this product family showing the scope of geometries, sizes, and features produced.
Feature Detail
Close-up views of critical features including threads, sealing faces, ribs, fins, bores, and mounting points.
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.
Heat Sink Housing Types
| Type | Power Range | Cooling Mode | Alloy |
|---|---|---|---|
| LED streetlight housing | 50-200W | Natural convection | A360 |
| LED high-bay housing | 100-500W | 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 | 7-22 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 5-8 mm, height-to-thickness ratio >=6:1 (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
Related
Heat sink housing inquiry: casting@kastdiecast.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China
Related Resources
Next steps for aluminum die cast heat sink housing
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CapabilityQuality Control
Review inspection workflow, traceability support, and process control standards before launch.
Process GuideDie Casting Process
See how casting, trimming, machining, finishing, and inspection fit together in production.
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