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Development & Stamping of Aluminum Heat Sink Fin Assembly for the Consumer Electronic Industry

Development & Stamping of Aluminum Heat Sink Fin AssemblyIn pursuit of a more cost-effective solution with lower failure rates, Perfection Spring & Stamping Corp. worked with a customer in the projection television industry to develop a new design for an aluminum heat sink fin assembly. The original design consisted of extruded aluminum in a glued assembly, which led to customer rejects or outright product defects.

Perfection Spring & Stamping settled on an unprecedented progressive stamping process using two presses (a 150-ton and a 200-ton) and multiple stations: 8 for the base plates, and 10 to stamp the fins. This design, which had not been used before because the customer had not believed it possible, eliminated the gluing assembly step and increased the part's success rate, leading to cost savings for the customer over the 6-year product program.


Progressive Stamped Heat Sink Project Highlights

Product Description This Aluminum Heat Sink Fin Assembly was
developed for a Projection Television application
Capabilities Applied/Processes
  • Develop a Cost Effective Heat Sink for
Maximum Heat Dissipation
Custom Mechanical Assembly
Equipment Used to Manufacture Part
  • 150 Ton
Brown Boggs
  • 200 Ton
  • Progressive Dies
  • 8 Stations for Base Plates
  • 10 Stations for Fins
Overall Part Dimensions
Base Plate:
Material Thickness: .065"
Length: 6.5"
Width: 3.5"
Height: 1.0"
Unfolded Fin
Length: 18"
Folded Fin:
Material Thickness: .020"
Length: 5.75"
Width: 3.25"
Height: 1.50"
Tightest Tolerances Base Plate: ±.005"
Folded Fin: ±.00075"
Material Used Aluminum
Estimated Part Weight .35 lbs
Features/Benefits Custom Staking Method of Incompatible Material Thicknesses
  • Eliminates Glue Seal & More Expensive Techniques
In Process Testing/Inspection Performed
In-Process Real-time SPC of Critical Dimensions
CMM Measurement
Strength Testing on Stakes
Cleanliness Sediment Testing
Dimensional Results Reporting
Control Plan
Process Flow Diagram
Failure Mode and Effects Analysis (FMEA)
Gage Repeatability
Reproducibility Variable Data Report
Raw Material Chemical Composition Results
MSDS - Material Safety & Data Report/Substances
and Materials
Industry for Use Consumer Electronics
Volume 600,000 Pieces
Packaging Special Pack Thermal-Formed Packing Trays
  • Anti-Static
Lead Time Tooling: 14 Weeks
Production Parts: 6 Weeks
Delivery Location Tenessee
Standards Met Customer supplied print, 2D CAD Drawing
Product Name Heat Sink Fin Assembly

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