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What Is A Custom Heatsink?

The shape, structure, and manufacturing process of a heatsink must all be specifically tailored to the performance requirements and operating environment of the application—only then can the heatsink deliver its optimal thermal performance.

The thermal management industry serves a wide range of industrial sectors. Within each sector, companies strive to differentiate themselves competitively. Our custom heatsinks are precisely designed to address the unique needs of different customers, empowering them to maintain a competitive edge in their respective markets—in terms of performance, cost, and quality.

Benefits of Partnering with Greatminds

With over a decade of dedicated experience in the thermal management market, Greatminds has delivered customized cooling solutions to Tier-1 customers across diverse industries, successfully developing more than 100 unique custom heatsink designs.

We offer a complete end-to-end thermal solution—from thermal simulation and structural design, to in-house manufacturing and rigorous product testing.

Custom Heatsink Design

Air Coonling Simuation Assessment Information Input Form
Environmental Definition	Ambient Temperature (C ) Altitude (m) Gravity Direction Usage Environment (Indoor and Outdoor)
Installation Method	Installation Method Locking Force Requirements Avoidance Requirements
Size Information	Appearance Size Requirements (mm)
Power Consumption Information	Heat Source Power (W) Heat Source $pecifications (Quantity, Size, Location), Preferably Provide Chip Model and Datasheet Maximum Allowable Chip Jection Temperature Maximum Allowable Chip Temperature
Fan Specifications	Airflow(CFM)
Related component information	PCB Material and Thickness TlM Specifications Chassis Specifications (material, thickness, surface treatment) Heatsink Material and Surface Treatment Requirements
Cooling Method	Natural Cooling/Forced Air Cooling/Liquid Cooling

After a custom heatsink project is initiated, we require the customer to fill out a requirements form. Upon receipt, our engineers will conduct a feasibility evaluation. Our project team will then proceed with heatsink simulation and structural design, and provide the customer with the corresponding simulation report, structural drawings, and quotation. If everything goes smoothly, we will proceed with production according to the ODM process.

Types of Custom Heatsinks

With this information, Greatminds Products can then work with your team to select the best custom heatsink option for your thermal application.

Heat Pipe Heatsink

A heat pipe heatsink utilizes the phase change cycle of a working fluid inside it, which absorbs heat and vaporizes at the evaporator end and releases heat and liquefies at the condenser end, efficiently transferring heat.

Vapor Chamber Heatsink

A vapor chamber heatsink uses the phase change cycle of a working fluid within an internal vacuum cavity. The fluid evaporates in the heat source area and condenses in cooler areas, achieving rapid and even heat dissipation over a large area.

3D Vapor Chamber Heatsink

Based on three-dimensional internal cavity phase change heat transfer (evaporation-condensation cycle), this heatsink uses three-dimensional capillary structures to achieve efficient heat diffusion in complex spaces. It features extremely high thermal conductivity, adaptability to irregular shapes, excellent temperature uniformity, and is suitable for high power density and compact electronic devices.

Die Casting Heatsink

Utilizing high pressure to inject molten aluminum or zinc alloy into a mold to form an integrated heatsink structure with fins in one step. It offers high design freedom, low cost, and is suitable for mass production without requiring subsequent assembly.

Extruded Heatsink

Formed by heating aluminum and then extruding it through a die to create continuous finned profiles, which are then cut and surface treated. It is cost-effective, highly productive, lightweight, and suitable for medium-power applications requiring significant heat dissipation area.

Skived Fin Heatsink

Made by "shaving" dense fins from a solid metal block (usually copper or aluminum) using precision tools, resulting in a one-piece structure without interface thermal resistance. It features high fin density, no contact thermal resistance, and excellent thermal performance, making it particularly suitable for high heat flux localized cooling.

Zipper Fin Heatsink

Independent stamped fins are welded onto a base, allowing for a combination of copper base and aluminum fins to balance thermal conductivity and weight reduction. It provides a large heat dissipation area and offers good cost-effectiveness.

Cold Plate

Coolant flows through sealed channels, directly removing heat from the heat source. It offers strong heat dissipation capabilities, precise temperature control, and low noise.

Custom Heatsink Examples

A high majority of Greatminds Products’ business is the design, development and manufacturing of custom heatsinks for ODM applications that include Thermal Anaysis. The examples below are just a handful of recent custom heatsink design and development projects.

Data Center – Custom "Octopus" Heatsink

This octopus-like heatsink is actually a custom-designed solution for the Broadcom Tomahawk3 switch. It utilizes seven 500mm-long heat pipes to transfer heat from the central switching chip in the chassis to the airflow channels on both sides.

Optical-Communications-–-Optical-Module-Heatsink

Camera – Compact 3DVC Camera Heatsink

We’ve engineered the 3DVC heatsink to be under 100 mm in height, enabling it to fit inside a professional camera body. This not only ensures stable 8K video recording without overheating but also makes it one of the most compact solutions in the industry.

Optical Communications – Optical Module Heatsink

Traditional optical modules rely on extruded or stamped fins mounted on a cage. We have developed a vapor chamber heatsink for a leading communications equipment company, specifically designed for coherent optical modules, increasing cooling capacity from 5W to 30W.

Laser – Desktop Laser Heatsink

The pump source is the primary heat generator in desktop lasers. By integrating bent heat pipes with zipper fins, we doubled the heat dissipation area within the limited space of a desktop setup.