1. Project Overview
Innoway Precision developed and manufactured a custom aluminum stamping heat sink used in power tool controller modules.
The component is designed to support thermal management inside electrical control systems, helping improve heat dissipation performance and product reliability during operation.
The final application includes various cordless and electric tools such as drills, chain saws, polishers, grinders and hammer drills.
Product Information：
- Material: AL1050 Aluminum
- Material Thickness: 2.0mm
- Material Temper: H22-H24
- Manufacturing Process: Progressive Die Stamping
- Monthly Volume: 55,000+ pcs
- Burr Requirement: ≤0.05mm
- Post Process: Ultrasonic Cleaning
2. Manufacturing Challenges
2.1 Maintaining Consistent Stamping Quality for High-Volume Production
With a monthly demand of approximately 55,000 pieces, the heat sink required stable production capability and consistent dimensional accuracy.
Aluminum material has good thermal conductivity but requires careful control during stamping to avoid deformation, surface damage and inconsistent forming results.
2.2 Controlling Burrs on Precision Aluminum Components
Because the heat sink is installed inside an electronic control module, excessive burrs may affect assembly reliability or create potential safety risks.
The customer required burr control below 0.05mm, requiring strict control of tooling conditions and stamping parameters.
2.3 Ensuring Clean Surface Condition After Stamping
During aluminum stamping, surface contamination from lubricants and processing residues can affect subsequent assembly performance.
Therefore, a reliable cleaning process was required to maintain a clean and consistent surface appearance.
3. Manufacturing Solution
3.1 Progressive Die Stamping Process
To achieve stable mass production, Innoway utilized progressive stamping tooling for continuous production.
The process provides:
- Consistent part dimensions
- High production efficiency
- Stable output for large-volume requirements
3.2 Precision Burr Control
Through optimized tooling design, die clearance adjustment and production monitoring, the burr height was controlled within customer requirements:
Burr height ≤0.05mm
This ensured reliable assembly performance inside the controller module.
3.3 Ultrasonic Cleaning After Stamping
After stamping, all parts undergo professional ultrasonic cleaning.
This process removes:
- Stamping oil residues
- Metal particles
- Surface contaminants
The cleaning process ensures the aluminum heat sinks meet cleanliness requirements before final assembly.
4. Project Results
Through optimized stamping processes and strict quality control, Innoway successfully delivered a stable production solution for the aluminum heat sink component.
Key Results:
✓ Stable monthly production capacity of 55,000+ pieces
✓ Consistent aluminum stamping quality
✓ Burr control within 0.05mm requirement
✓ Clean surface condition after ultrasonic cleaning
✓ Reliable supply support for power tool controller applications
FAQ
An aluminum stamping heat sink is a thermal management component manufactured through stamping processes to help dissipate heat from electronic components.
AL1050 aluminum provides excellent thermal conductivity, good corrosion resistance and good formability, making it suitable for heat dissipation applications.
This component is produced using progressive die stamping, which is suitable for high-volume production with consistent quality.
Ultrasonic cleaning removes oil, particles and contaminants after stamping, improving cleanliness and assembly reliability.
Yes. Innoway provides customized aluminum stamping solutions from prototype development to mass production.
