Development & Stamping of Aluminum Heat Sink Fin Assembly for the Consumer Electronic Industry
In 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
||This Aluminum Heat Sink Fin Assembly was
developed for a Projection Television application
- Develop a Cost Effective Heat Sink for
|Maximum Heat Dissipation
Custom Mechanical Assembly
|Equipment Used to Manufacture Part
- Progressive Dies
- 8 Stations for Base Plates
- 10 Stations for Fins
|Overall Part Dimensions
Material Thickness: .065"
Material Thickness: .020"
||Base Plate: ±.005"
Folded Fin: ±.00075"
|Estimated Part Weight
||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
Strength Testing on Stakes
Cleanliness Sediment Testing
Dimensional Results Reporting
Process Flow Diagram
|Failure Mode and Effects Analysis (FMEA)
Reproducibility Variable Data Report
Raw Material Chemical Composition Results
MSDS - Material Safety & Data Report/Substances
|Industry for Use
||Special Pack Thermal-Formed Packing Trays
||Tooling: 14 Weeks
Production Parts: 6 Weeks
||Customer supplied print, 2D CAD Drawing
||Heat Sink Fin Assembly
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