What is a Folded Fin Heat Sink?

The folded fin heat sink (FFS) is a unique and highly efficient heat dissipation device. Its key feature lies in the fact that the fins are not individually formed through traditional extrusion or welding. Instead, they are constructed from one or more thin metal sheets (typically copper or aluminum with high thermal conductivity) through advanced processes such as precision folding, curling, or corrugating to create a complex, high-density channel structure. These folded fins are then secured to the heat sink base using highly reliable brazing, epoxy bonding, or other tight-fitting methods.

This innovative design makes it unique in the field of thermal management, enabling:

Achieve ultra-high fin density: Allows more heat dissipation surface area to be integrated into an extremely limited space, thereby significantly improving overall heat dissipation efficiency and addressing high heat flux density challenges. Optimized airflow path and uniformity: The regular and parallel channels formed by the folds help to precisely guide the airflow, reduce turbulence loss and bypass effect, and ensure that air passes through the entire fin array efficiently and evenly, maximizing heat exchange efficiency.

Outstanding Advantages of Folded Fin Heat Sinks

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Extremely high heat dissipation performance

Achieving higher fin density and a larger effective heat dissipation area through a precise folding process can effectively handle high heat flux density and is the key to solving the heat dissipation bottleneck of high-power consumption equipment.

Excellent heat conduction efficiency

Advanced connection methods such as brazing are usually used between the fins and the base plate to ensure extremely low thermal resistance and achieve fast and efficient heat transfer from the heat source to the fins and then to the air.

Lightweight design

Compared with integral extruded or machined heat sinks with the same heat dissipation capacity, folded fins are usually made of thin plate materials and have a lighter structure, making them suitable for applications with strict weight requirements.

Flexibility and customization

Fin height, pitch, wave shape and material can be flexibly customized according to specific needs to perfectly adapt to different airflow conditions, space constraints and heat load requirements.

Cost-effective (mass production)

In mass production, the folded fin process can effectively reduce the manufacturing cost per unit heat sink and provide a more competitive solution.

Winshare Folded Fin Heat Sinks: Deep Customization Solution

At Winshare, we understand that every thermal management challenge is unique. Therefore, we offer a comprehensive and customer-centric folded fin heat sink customization program to ensure your specific cooling needs are perfectly met.

Customize your Folded Fin Heat Sink

Winshare Custom Die Casting heat sink

In-depth communication and assessment of needs

We will discuss your requirements in detail to fully understand your heat source characteristics, heat load, available space limitations, operating environment conditions (such as temperature, airflow type and velocity), target temperature, and any special performance requirements for the heat sink, such as noise, weight, and lifespan. We will also confirm the connection method between the heat sink and the heat source to ensure optimal heat transfer efficiency.

Professional thermal design and simulation optimization

Our team of experienced thermal design engineers utilizes industry-leading computational fluid dynamics (CFD) and finite element analysis (FEA) software to accurately simulate the heat sink's thermal performance, internal airflow distribution, and pressure drop under various operating conditions. During the design phase, key parameters such as fin height, spacing, wave form, and material thickness are comprehensively considered. Multiple rounds of iterative optimization ensure that the design closely matches actual operating conditions. Calibration using big data improves the success rate of first-time designs.

Advanced materials and manufacturing process selection

Based on factors such as thermal conductivity, weight, cost, and corrosion resistance, we recommend and utilize high-quality materials such as pure copper (C1100) and aluminum alloys (A6061, A6063). Winshare boasts industry-leading manufacturing capabilities, enabling us to select the most suitable and efficient processes based on design complexity and volume requirements, including precision folding, vacuum brazing, reflow/spot welding, and high-precision CNC machining.

Prototyping and rigorous validation

Once the design is finalized, we will quickly produce high-precision prototypes. In Winshare's well-equipped thermal testing lab, we conduct comprehensive thermal performance tests (such as thermal resistance and temperature rise) and reliability tests (such as thermal cycling, vibration shock, and salt spray corrosion) to ensure that performance fully meets design specifications and your expectations. All test data is carefully recorded and shared with customers.

Mass production and lean quality control

Once the prototype is validated, we'll initiate efficient mass production. Winshare strictly adheres to the ISO 9001 quality management system, implementing meticulous management and strict quality control at every stage, from raw material procurement, production and processing to final product shipment. We utilize advanced automated production equipment and high-precision testing instruments to ensure high consistency, superior quality, and long-term reliability in every batch of products, minimizing your risk.

On-time delivery and perfect after-sales service

We are committed to on-time product delivery, professional packaging, and global logistics support to ensure your products reach you safely and intact. Winshare's professional support team will provide ongoing technical consultation and responsive after-sales service to ensure your cooling solution operates stably and efficiently throughout its lifecycle, providing you with solid support.

Winshare Folded Fin Heat Sinks Core Advantages and Features

Excellent thermal performance optimization

With extensive thermal design experience and a deep understanding of the structural characteristics of folded fins, we can provide your product with industry-leading cooling efficiency and effectively manage high heat flux density challenges.

Deep customization capabilities

From fin shape, height, and spacing to substrate design, material selection, and surface treatment, we provide a full range of in-depth customization solutions to precisely match your unique needs.

Advanced manufacturing process integration

We master core technologies such as precision folding, vacuum brazing, and CNC machining to ensure our products have excellent thermal performance and mechanical strength.

Integrated solution provider

As an excellent supplier of cooling components and resource integration, we provide full-link services from design, prototyping, testing to mass production and supply chain management, truly saving you worry, effort and money.

Strict quality assurance system

We implement ISO 9001 quality system and strictly control every step from source to finished product to ensure high reliability and consistency of products.

Rich project experience

Our extensive experience in collaborating with leading global companies enables us to deeply understand and meet the most demanding thermal management needs.

Winshare Brazing Heat Sink Quality Assurance and Certification

Winshare Folded Fin Heat Sink Application Areas

Communications and Data Centers

High-density computing and communication equipment such as server processors, network switches, and 5G base stations.

New Energy

Inverters, IGBT power modules, electric vehicle charging stations, battery management systems and other high-power power electronic equipment.

Industrial Control

Industrial-grade computers, automation equipment, inverters, high-power drives, etc.

Medical Devices

Precision medical diagnostic equipment, imaging equipment, and other instruments that have strict requirements on temperature control and reliability.

high-end consumer electronics

High-performance gaming laptops, workstations, high-end graphics processors (GPUs), etc.

Military and Aerospace

Equipment with special requirements for lightweight, high reliability and heat dissipation performance in extreme environments.

Why Choose Winshare Folded Fin Heat Sinks?

When you choose Winshare, you are not only choosing an efficient cooling product, but also a trustworthy long-term thermal management strategic partner.

Professional depth and innovation

We have an experienced team of thermal design experts who master cutting-edge thermal simulation technology and advanced manufacturing processes, and can provide you with innovative and precise thermal management solutions.

Ultimate customization capabilities

We provide a full range of in-depth customization services from design, materials, processes to testing to ensure that the product is a perfect match for your specific application.

Excellent quality and reliability

We strictly implement the international quality management system, and each product is rigorously tested and verified to ensure excellent quality and long-term stability, reducing your operational risks.

Cost-effectiveness optimization

Through optimized design, efficient manufacturing processes and integrated supply chain, we provide you with the most competitive overall solutions while ensuring top performance.

One-stop convenient service

From thermal design concept to final product delivery, Winshare provides full-link services, saving you the trouble and effort of coordinating with multiple parties.

Common Problems of Brazing Heat Sink

Winshare: Thermal Management, Customized for You, Because You Excel.

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