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Bonded Fin Heat Sinks

Wellste bonded fin heat sink is designed to provide high cooling and smaller thermal performances. This heat sink type overcomes heat sink surface limitations.

  • Low Minimum order Qty starts
  • Fast lead time ship out even in peak season
  • Compliance with Aluminum Industry High specific Standard
  • Work with our teams to tailor your own bonded fin heat sink

Leading Bonded Fin Heat Sinks Manufacturer and Supplier

Wellste bonded fin heat sinks are fabricated using aluminum alloy. Fins are also fixed to the base by epoxy or soldering.

Bonded Fin Heatsinks

Bonded Fin Heat Sinks

Bonded fin aluminum heat sink provides significant weight and cost.

Bonded Fin Heat Sink

With our extensive range of bonded heat sinks, any size orders are provided with prototypes to large production runs.

heat sink types

Wellste can design and develop bonded heat sink that can meet your assembling needs.

aluminium heat sink manufacturersBonded Fin Heat Sink

Item TypeBonded Fin Heat Sinks
MaterialAluminum, Copper
SizeStandard or customized size
Colorssilver, black , blue, wood color, RAL powder coating color, and so on
ShapeRound, Square, Flat, or customized
Thickness0.4mm-20mm or Customized
ApplicationLED Lighting, Inverter, Welding Machine, Communication Device, Power Supply Equipment, Electronic Industry, Thermoelectric Coolers/Generator, IGBT/UPS Cooling Systems, etc.
Production ProcessProfiles Extruding—Cutting—CNC Machining(Milling, Drilling, Tapping)—Deburring— Cleaning— Inspecting–Packing
FinishAnodizing, Mill finish, Electroplating, Polishing, Sandblasted, Powder coating, Silver plating, Brushed, Painted, PVDF, etc.
Deep processCNC,drilling,milling,cutting,stamping,welding,bending,assembling,Custom Aluminum Fabrication
Lengthcustomized length
Packagingstandard export packaging or as discussed
OEM & ODMAvailable. our engineer can check and discuss your design, great help!
Free SamplesYes, we can provide free sample
Delivery time15-20 days after sample confirmed & down payment, or negotiated
PortShanghai Port

aluminum heat sink

For more information regarding bonded fin heat sink, please don’t hesitate to contact us today, You can work with our team to tailor your own boned fin heat sink.

-Standard Packing Option-

* Long bar length profiles 3.0-6.0 meters*
* Short bar length profiles 0.3-3.0 meters*

-Loading & Shipment-

Frequently Asked Questions
Do you have any MOQ limit for Bonded Fin Heat Sink?

Wellste provide Low MOQ for Bonded Fin Heat Sink. 1pc sample is free for you to check our quality.

Can I have a sample order for Bonded Fin Heat Sink?

Yes, Wellste is pleased to provide Bonded Fin Heat Sink for you check the quality.

Are you a trading company or manufacturer?

We are a manufacturer with OEM/ODM service.

What's the Surface Treatment of your Bonded Fin Heat Sink?

Copper Passivation/Aluminum Anodized

How long time of your Bonded Fin Heat Sink sample to prepare?

It is only taking 7-10 days to complete your sample if the sample size is in stock.

For custom Bonded Fin Heat Sink, It takes a little bit long time to make extrusion tooling, commonly it requires 30-35 days finish.

What is payment terms of Bonded Fin Heat Sink?

30% TT in advance, the balance payment is paid before shipment.

Wellste: Your Leading Bonded Fin Heat Sink Manufacturer and Supplier

For custom design bonded fin heat sink, you can send your bonded pin fin heat sink design. Specific structure and size that appropriate for the applied equipment and required heat load to carry is a must.

The fins not only cut & shaped from aluminum coil or sheet but also can be extruded extrude fins to shape and length for more complicated designs, we can extrude fins to shape and length, specifically.

Moreover, we also performed custom grooves that can be produced by the aluminum sheet or extruding production way.

bonded fin heat sink

Custom design bonded fin heat sinks are available to support thermal modeling. And our engineers will help and assist you in designing a heat sink for final manufacturing. For that reason, your cooling requirements for high-power electronic component packaged applications will be satisfied.

Wellste will customize your own design through our modern production technologies and latest generation machines for aluminum fabrication such as CNC, Punching, Trapping, Welding, Drilling, and Milling. With our robust production capabilities, we can ensure fast delivery even during peak season.

Wellste specializes in bonded fin heat sink which is designed for forced convection applications. Our experienced workers and knowledgeable technical team will tailor the required cooling of your equipment to a specific design.

It allows much taller fin heights and much smaller spacing. Our bonded fin heat sink performed significantly where sufficient heat is generated by higher fin densities and fin aspect ratios.

Wellste bonded fin heat sink specifically effective to high powered commercial, military, industrial and medical electronics applications.

Components include motor drives, power supplies, electro-surgery equipment, amplifiers, and others.

In Wellste, we offer a full range of bonded fin heat sinks for reducing thermal resistance on your thermal and mechanical and requirements.

Wellste has established a reputation for making products that help customers produce high-quality, high-performance with extremely reliable equipment.

Over 20 years, Wellste has been helping customers and clients’ design issues. We’ve been the leading manufacturer and provider of all kinds of thermal management and protection solutions.

We worked very hard to develop quality relationships with our customers around the world. Committing with them and doing what we can to guarantee quality products and services, made them pick the right choice.

Wellste as a reliable and trusted partner, produce unique innovation and superior quality bonded fin heat sink. Our company has been approved by SGS and obtained ISO 9001 quality management certification. We already serve 1000+ clients from popular companies.

Moreover, we pride ourselves to offer them innovative solutions that allow them to make highly competitive products in their markets.

Bonded Fin Heat Sink: The Ultimate FAQ Guide

I know choosing a suitable bonded fin heat sink can be an overwhelming task.

A reason this guide will explore everything you need to know about bonded fin heat sink.

It covers everything about bonded fin heat sink – take a look:

What Is A Bonded Fin Heat Sink?

A bonded fin heat sink is a collection of grooved bases that have single fins which are bonded within the grooves.

Due to the greater surface area, this sort of heat sink manufacturing allows for significant fin concentrations and fin aspect ratios.

This feature is suitable since you cannot attain those traits with extrusion methods, considerably boosting thermal efficiency over extruded heat sinks.

A Bonded Fin heat Sink

A Bonded Fin Heat Sink

There are various ways you can use when making a bonded fin heat sink, and they include the following:

  • Die casting
  • Extrusion
  • Machine groove base

When using machining, you can have extra features such as:

  • Graphite heat spreaders
  • Embedded heat pipes
  • Vapor chambers

The fins on bonded fin heat sinks are normally cur from a thin stock plate or punched from a stock coil.

Afterward, you will insert the fins in groove bases then join them using epoxy, soldering, or brazing.

What Are The Applications Of A Bonded Fin Heat Sink?

To make use of their great current capabilities, today’s high-power semiconductors must be properly cooled.

Since the dawn of the semiconductor era, air-cooled extruded aluminum heat sinks have been a widely recognized cooling technology.

The necessity for thermal performance for effective thermal dispersion has now exceeded the limit of traditional extruded heat sinks.

This is due to the constant growth of power density.

Individual fins are bonded into an extruded aluminum grooved base, which is used to create these heat sinks.

There are various uses of bonded fin heat sinks and they include the following:

  • Motor drives
  • Uninterrupted power supplies [UPS]
  • Industrial application
  • Forced air
  • TECs
  • Variable speed motor control
  • Welding units
  • Traction drives
  • Laser power suppliers
  • Power rectification machinery
  • AC welding switch
  • Thermoelectric modules
  • Power rectifiers
  • Renewable energy
  • Factory automation

 Bonded Fin Heat Sinks Have Various Applications

Bonded Fin Heat Sinks Have Various Applications

What Are Some Characteristics Of A Bonded Fin Heat Sink?

Fig 3- Fins Can Be Extruded To Different Forms And Lengths

Fins Can Be Extruded To Different Forms And Lengths

Some of the characteristics you can find in a bonded fin heat sink include the following:

  • A better aspect ratio and fin density improve the cooling surface area, leading to a high-performance bonded fin heat sink.
  • Reduced thermal resistance for heat transfer in devices using high power.
  • Bonded fin assemblies may be made from aluminum fins, copper bases, and aluminum bases.
  • It is possible to tailor the wings to meet your needs in terms of thermal efficiency and packing height limits.
  • Fins can be extruded to particular forms and lengths for more complicated designs.
  • It is suitable for natural convection and forced convection.
  • For low thermal loss, you can use a bonding glue that is extremely thermally conductive.
  • Fins made of metal sheet or extrusion, unique layouts possible; the metal plate is made up of fins that may be trimmed to any size.
  • To ensure minimal heat loss, you can use a bonding resin that has high thermal conductive properties.
  • Bonded fin heat sinks can disperse more heat than standard heat sinks of the same size.
  • Reduce the size of the heat sink and the total system volume.
  • It increases the surface area of aluminum by up to three times that of standard heat sinks.

What Bonding Methods Can You Use When Manufacturing A Bonded Fin Heat Sink?

These include the following:

Thermal Epoxy

Any adhesive epoxy that contains one or more substances added to it to improve thermal, or heat, transmission is known as thermal epoxy.

They form strong mechanical bonds and provide suitable heat transfer and high voltage isolation.

Dependent on the thermal additive utilized, these epoxies might be electrically conductive or non-conductive.

Thermal epoxies containing silver and other metal-based thermal additions are frequently electrically conductive.

Thermal Epoxy Bonded Heat Sink

Thermal Epoxy Bonded Fin Heat Sink

For this reason, apply them with extreme caution to avoid or prevent electrical shorts.

Ceramic-based additives are not only non-conductive electrically, but they are also inefficient in heat conduction.

Thermal epoxy can fill empty spaces that develop on bonded fin heat sinks that appear as a result of the manufacturing process.

When you place the fins and the base together, the empty spaces will fill the air.

Because air is a bad thermal conductor, a material is used to fill the spaces.

This material will also assist in the transfer of heat to the bonded fin heat sink for elimination.

Thermal grease, thermal tape, thermal pads, or thermal epoxy can be used.

Besides, it makes it possible if you are planning to fasten the heat sink to a mounting surface.

When adding thermal epoxy, it is critical to use as little as necessary to fill any cavities and form the connection.

The electrical conductivity of the epoxy will be reduced if a heavy coat of epoxy is used.

Also, the epoxy compound provides low shrinkage and low coefficients of thermal expansion as opposed to aluminum or copper.

The link between the two surfaces is permanent after the epoxy has dried.

Epoxies should be applied in well-aerated places and must always be followed according to the manufacturer’s directions for optimal results.


This is the process of joining the fins and the base of bonded fin heat sinks by melting solder to the joint.

The filler metal or solder has a low melting point than the surrounding metal.

Soldering will not melt the materials of the bonded fin heat sink.

A Soldered Heat Sink

Soldered Heat Sink


This is the process of melting a piece of metal between other pieces of metal to join them.

Unlike soldering, brazing operates at a high-temperature level of about 450°C which allows for a wide range of materials.

Brazing can form tight joints as the process depends on capillary action that wicks the braze substance between the fins.

The braze material also has a low melting point than the adjacent components.

Besides, you can make strong and consistent joints when you use metals that form a close match with the mating components.

How Can You Manufacture A Bonded Fin Heat Sink?

Depending on the material construction and their shape, you can make bonded fin heat sinks using various methods.

Some of the common and affordable methods include forging, extrusion, stamping, and casting,

Other methods that will cost you more include swaging, skiving, and CNC machining.

Besides being expensive, they can make bonded fin heat sinks that have features that the other methods cannot make.

Here are the methods you can use when making bonded fin heat sinks:


The bulk of aluminum alloy heat sinks uses the well-known aluminum extrusion heat sink production method.

Besides, this is the common manufacturing standard in the market.

Aluminum extrusion is the most popular method for processing aluminum, and it has been employed in a variety of applications.

Aluminum extrusion is mostly utilized to make sheet fins or cylindrical fins.

AL6061 or AL6063 are the most common materials used in aluminum extrusion.


Stamping heat sink manufacture is commonly utilized in the production of heatsinks with heat pipes flowing through the fins.

The required form can be pressed out of copper or aluminum.

Air-cooled electronic equipment is frequently utilized to provide a low-cost means of dissipating heat from low-calorific equipment.

The heat sink made by stamping is extremely appropriate for large-scale production.

This is owing to the use of a modern die and high rates of stamping technology.


Skiving heat sink production techniques is a one-of-a-kind metal forming method that is most commonly used to create copper heat sinks.

“Precision Skiving” isn’t known where it came from, but it’s simple to grasp based on the name of the difficult-to-imagine processing technique.

Skiving, often known as slicing, is the act of slicing.

Method of processing: based on the requirements of a single piece of metal profile.

Thin slices of appropriate thickness are sliced and bent upward into an upright posture.

This will produce heat dissipation fins using a special planer with fine control.

Fig 6-Skived Fin Aluminum Heat Sink

Skived Fin Aluminum Heat Sink

CNC Machining

This is a process you can use when fabricating bonded fin heat sinks with complex geometry or urgent components.

However, this method is usually expensive.


The metal sheet processes enable aluminum or copper to enhance the contact area with air within the same space.

These fins can be glued or welded to the base or substrate to be cooled with epoxy resin.

Because of the high thermal resistance along the plate’s length due to its thin thickness, this method is not suited for big heat sinks.

It can, however, be employed in post-assembly or other heat sink production procedures to create high-performance heat sinks.


The majority of air-cooled fins do have convection environment constraints.

Therefore increasing the number of fins will considerably enhance the fins’ total heat dissipation capacity.

Epoxy glue packed with heat-transfer aluminum is used to attach the high-performance fins to a surface with a slot.

The ratio of fin height and spacing may be boosted to 20~40 with this heat sink manufacturing technology.

This will considerably improve the heat sink’s capacity to transfer heat to the air in a small space.

What Are The Benefits Of A Bonded Fin Heat Sink?

Bonded fin heat sinks have several benefits which include the following:

  • They will dissipate more heat than other conventional or standard heat sinks with a similar footprint
  • They will lower heat sink and total system volume
  • Bonded heat sinks increase the cooling surface area of aluminum extrusion by two to three times
  • It offers a high thermal performance
  • Tight fin pitch
  • It provides a lower tooling cost
  • Suitable for forced convection without any limit to the length of airflow
  • Easy to integrate with a high design flexibility

There Are many Benefits In using Bonded Fin Heat Sinks

There Are Many Benefits To Using Bonded Fin Heat Sink

Which Materials Are Suitable For Making A Bonded Fin Heat Sink?

Most heat sink producers have traditionally used one of two materials which are copper or aluminum.

Copper has a better heat conductivity than aluminum, however, copper is heavy, costly, and difficult to extrude.

For these reasons, it is reasonable to state that aluminum is the best bonded fin heat sink material.

Aluminum bonded heat sinks are not as conductive as copper when you use them by themselves.

However, it comes with plenty of other advantages to compensate.

Aluminum is often brighter than copper in terms of radiation, which means it is excellent at reflecting heat from light sources.

This is valid even for aluminum that hasn’t been polished. Aluminum may also be anodized in a variety of colors.

Manufacturing an aluminum bonded heat sink extrusion is quite economical, especially when compared to copper.

It is also exceedingly light and simple to work with.

Aluminum is appropriate for bigger and customized aluminum heat sink extrusion.

Besides, extruded metal was used to create these specific combinations.

The fin configuration determines the heat sink’s primary functioning.

Manufacturers construct them with numerous layers because they are most effective when they cover the largest potential surface area.

The main material you will use when making a bonded fin heat sink is from extruded 6063-T5 aluminum alloy.

On the other hand, the fins of the bonded fin heat sink can be made from 1100-H14 aluminum alloy roll stock.

Besides, this fin material from aluminum is averagely 15% more conductive than other material fin construction in conventional heat sinks.

This increases the fin efficiency, compensating for any loss in conductivity that you will get when using an epoxy joint.

This feature will increase the total thermal performance of the bonded fin heat sink.

How Close Can You Space The Fins Of A Bonded Fin Heat Sink?

The spacing between the fins on a bonded fin heat sink depends on the breadth of the base or foundation.

When the base is up to 8.0 inches wide, you can space 0.032 inch thick fins at an average of 0.125 inches.

For a base that is between 8.0 inches and 16 inches, you can space 0.050 inch thick fins at 0.20 inches from center to center.

When the width of the base is over 16.0 inches, you must assess it on a case-by-case basis.

Can You Use Copper In A Bonded Fin Heat Sink To Enhance Conductivity?

Yes, you can use epoxy to bind the copper fins into an aluminum base structure, both machined and extruded.

In some other usages, you can assemble copper finds in conjunction with aluminum fins.

This design will save on cost and enhance the thermal performance of the bonded fin heat sinks.

For specific applications that need extremely high thermal performance, you must manufacture the base structure and the fins from copper material.

In such applications, you will conduct soldering or brazing for these components, and not use an epoxy bond.

Also, the amount you will spend on a copper component is normally three times that of an aluminum component.

A Copper Bonded Fin heat Sink

A Copper Bonded Fin Heat Sink

Can You Black Anodize The Parts Of A Bonded Fin Heat Sink?

No, you cannot black anodize the components of a bonded fin heat sinks.

Even if it is possible to black anodize the parts, the black finish will not enhance heat removal in forced convection.

However, the black anodize would increase the cost of the bonded fin heat sinks.

A cost-effective gold chromate finish can be used to protect the bonded fin heat sink against corrosive elements.

Can The Fins Fall Out In A Bonded Fin Heat Sink?

To ensure the fins do not fall out and the bonded fin heat sink has no errors, ensure the following:

  • Proper material selection
  • Proper surface preparation
  • Conduct strict process monitoring
  • Ensure high-quality standards

When Using Epoxy To Joint Bonded Fin Heat Sink, Will It Restrict The Heat Flow?

The joint design of the bonded fin heat sink and conductivity of the epoxy substance will ensure high performance even at extremely high temperatures.

The average is >1.0 ° Celsius increase at 25-watt heat per fin.

Do The Upper Part Of The Lengthy And Thin Fins In A Bonded Fin Heat Sink Enhance Its Capacity To Eliminate Heat?

Yes, in several situations, the total fin efficiency of bonded fin heat sinks is usually between 60% and 75%.

Conventional extrusions can have a high fin efficiency of almost 85%.

However, bonded fin heat sinks have a 200% to 300% increase in the total surface area.

This high surface area will compensate for the low fin efficiency.

How Does A Bonded Fin Heat Sink Function?

Bonded fin heat sinks operate by eliminating heat away from the main parts of a system.

Here is how it operates:

Heat Generation By Source

The source is any system that will generate heat which you need to remove for it to operate optimally.

Heat Transfer From The Source

Here, the heat will move from the source to the bonded fin heat sink through the natural convection process.

The thermal conductivity of the bonded fin heat sink will impact this process.

For this reason, materials such as aluminum and copper are used when making bonded fin heat sinks.

Heat Distribution On The Bonded Fin Heat Sink

Heat will move via the bonded fin heat sink through natural convection from an area with high temperature to that of low temperature.

Heat Dissipation From Bonded Fin Heat Sink

Here, heat will move from the bonded fin heat sink into the environment due to a temperature gradient.

How Does A Hybrid, Passive, And Active Bonded Fin Heat Sink Compare?

Passive bonded fin heat sinks use natural processes to generate airflow across the bonded fin heat sink.

Active bonded fin heat sink relies on systems such as fans or blowers to increase airflow across the bonded fin heat sink.

Hybrid bonded fin heat sinks use both passive and active components to enhance airflow.

The active part activates when the temperature is too much for passive systems to operate suitably.

 The Different mechanisms That passive , Active and Hybris heat sinks Employ

The Different Mechanisms That Passive , Active And Hybrid Heat Sinks Employ

What Factors Will Affect The Performance Of A Bonded Fin Heat Sink?

These include the following:

  • Length and width
  • Fin density
  • Volumetric resistance
  • Fin spacing
  • Thermal resistance
  • Airflow

What Are Some Other Types Of Heat Sinks In The Market?

These include:

  • Stamped heat sinks
  • Machining heat sinks
  • Folded fin heat sinks
  • Swaged heat sinks
  • Skived heat sinks
  • Forged heat sinks
  • Single fin assembly heat sink

How Will You Determine The Performance Of A Bonded Fin Heat Sink?

The methods you can use include the following:

  • Numerical methods
  • Experimental methods
  • Heat transfer theoretical models

What Are Some Future Trends Of Bonded Fin Heat Sinks?

This entails the use of Carbon Nanotubes [CNT] as they have high thermal and electrical properties.

Other substances include metal-diamond composites, Graphene, and HOPG [highly ordered pyrolytic graphite].

What Factors Will Affect The Cooling Capacity Of A Bonded Fin Heat Sink?

These include:

  • Thermal resistance
  • Cooling material
  • Design of fin
  • Attachment
  • Post-treatment

What Are Some Of The Surface Treatments For A Bonded Heat Sink?

These include:

  • Anodized finish
  • Powder coating
  • Clear chromate
  • Electroless Nickel Plating

Powder Coated Aluminum Bonded Fin Heat Sink

Powder Coated Aluminum Bonded heat Sink

What Is The Cost Of A Bonded Fin Heat Sink?

The price can range anywhere from 5 USD to 99 USD.

For all your custom bonded fin heat sinks, contact us now.

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