Table of Contents
Note: This page summarizes a representative application example. Results are specific to the described design, validation scope, and production conditions.
Executive Summary
Client: 5G telecommunications equipment manufacturer Challenge: Aluminum heat sinks insufficient for high-power RF modules Solution: Copper-infiltrated PM heat sinks with complex fin arrays Results:
- Thermal resistance reduced 28% (0.45 deg C/W to 0.32 deg C/W)
- Weight reduced 35% vs solid copper (infiltrated structure)
- Complex fin geometry (120 fins, 1mm spacing)
- Cost: 15% lower than CNC machined copper
Customer Background
Industry: 5G telecommunications infrastructure Application: High-power RF amplifier cooling (200W heat load) Environment: Outdoor base stations (-40 deg C to +65 deg C ambient) Challenge: Limited space, high thermal density
The Challenge
Problem 1: Thermal Performance
- Issue: Aluminum heat sinks: 0.45 deg C/W thermal resistance
- Requirement: <0.35 deg C/W to prevent RF power de-rating
- Impact: Reduced transmission power in hot climates
Problem 2: Manufacturing Limitations
- Issue: CNC milling 120 fine copper fins prohibitively expensive
- Cost: $85 per heat sink
- Lead Time: 6-8 weeks
Problem 3: Weight
- Issue: Solid copper heat sink weighs 1.2 kg
- Impact: Structural support costs, installation challenges
SinterWorks PM Solution
Material: Copper-Infiltrated Iron (FLC-4608)
Why Copper-Infiltrated?
- Thermal conductivity: 180-220 W/mK (vs Al 205 W/mK, Cu 400 W/mK)
- Lighter than solid copper (controlled porosity, copper infiltration)
- Enables complex fin arrays impossible with machining
Manufacturing Process
- Iron Skeleton Compaction: Complex tooling with 120 fin cores
- Pre-Sinter: 1100 deg C
- Copper Infiltration: 1150 deg C (copper slug melts, fills pores)
- Final Density: 7.2-7.4 g/cm3 (vs 8.9 g/cm3 solid copper)
- CNC Flatness: Bottom mounting surface machined to +/-0.02mm
Design Features
- Fin Count: 120 fins
- Fin Spacing: 1.0mm
- Fin Height: 35mm
- Base Thickness: 8mm
- Mounting Holes: 4x M4 threaded (sintered threads)
Results
Thermal Performance
| Metric | Aluminum | PM Copper-Infiltrated | Improvement |
|---|---|---|---|
| Thermal Resistance | 0.45 deg C/W | 0.32 deg C/W | -28% |
| Junction Temp (200W) | 115 deg C | 94 deg C | -21 deg C |
| Max Power (85 deg C limit) | 165W | 245W | +48% |
Weight & Cost
- Weight: 780g (vs 1200g solid copper, 450g aluminum)
- Cost: $72 (vs $85 machined copper, $35 aluminum)
- ROI: Increased RF power output justified 2x aluminum cost
Get PM Heat Sinks for Electronics
SinterWorks manufactures advanced PM heat sinks:
- Copper-infiltrated, aluminum, or custom alloys
- Complex fin geometries (pin fins, radial fins)
- Thermal testing and simulation support
- Volumes: 5K to 200K parts/year
Related Resources
Use these internal links to keep moving through the most relevant guides, service pages, and technical references for this topic.
Consumer Electronics PM Parts
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FLC-4608 Copper-Infiltrated PM
Review an infiltrated PM route used when density, thermal behavior, and machinability all matter.
Aluminum Powder Metallurgy
Compare a lighter PM thermal-management route when conductivity, weight, and cost tradeoffs must be balanced.
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