Winshare Die Cast Cold Plates customization

Winshare Thermal One-piece molding, high cost-effectiveness, optimal choice for batch production of complex structures.

What is Die Casting Cold Plate?

We melt aluminum, zinc, or magnesium. We inject it fast into a mold under high pressure. It cools into one solid plate with complex inner channels and outer mounts. No extra parts.

Core Process:

High-pressure injection: Metal fills mold in seconds. One-piece build.

The core benefits of Winshare die cast cold plates

Fast mass production

Short cycle. Perfect for big orders.

Low unit cost

Cheaper per plate in high volume.

Complex design

3D channels + mounting points in one go.

Less assembly

No extra machining or joining.

Medium-high heat

Fits car electronics, telecom, consumer gear.

Light & strong

Aluminum alloy standard.

Winshare Die Cast Cold Plate: Core Product Parameters and Customization Capabilities

Winshare's die-cast cold plates offer a fully customized service. Below is the scope of our design capabilities, which we will precisely optimize to meet your specific application needs.

Thermal Resistance

Achieves as low as 0.02 °C/W The lower the temperature rise generated by the heat source per watt of power, the better the heat dissipation performance. The specific value depends on the design and material.

Runner design
Complex 3D flow channelsMulti-layer, cross, and special-shaped runners can be customized to optimize fluid distribution and heat transfer efficiency.

Dimension

Up to 1500mm × 800mm Breaking through the size limitations of traditional processes, it is suitable for large heat sources or integrated structures.

Operating Pressure

Up to 200 PSI One-piece molded construction to ensure structural integrity and tightness under high pressure.

Surface Flatness

Better than 0.05 mm Precision CNC machining ensures perfect contact with the heat source, minimizing contact thermal resistance.

Fluid Connectors

Multiple integration options It can be directly die-cast or precision machined with a variety of standard/custom interfaces.

Winshare Die Cast Cold Plate: Commonly used core material

Aluminum alloy

Common grades: ADC12, AlSi10Mg(Fe), etc. Advantages: Lightweight, cost-effective, good thermal conductivity, easy die casting. It is the most commonly used material for die-casting cold plates, taking into account both performance and economy.

Zinc alloy

Commonly used grades: Zamak 3, Zamak 5 Advantages: Excellent fluidity, allowing for thinner walls and more intricate details. High strength and good wear resistance, suitable for products with high requirements for structural strength and details.

Magnesium alloy

Commonly used grades: AZ91D, AM60B Advantage: Extremely light weight and high specific strength. It is suitable for aerospace, portable equipment and other fields where there are strict restrictions on product weight.

Winshare die cast cold plate is different from other cold plate processes

When choosing the best cold plate solution for your application, it's crucial to understand the advantages and disadvantages of different manufacturing processes. The table below compares the key characteristics of die casting cold plates with other mainstream cold plate processes.

Process type	Manufacturing method	Runner complexity	Thermal performance	Structural integrity	Cost vs. Volume	Integration
Die Casting Cold Plate	High-pressure molten metal is formed in one go	High (complex 3D runners	Medium-high (balance performance and cost)	Very high (one-piece molding without welds)	Low Cost/Unit (High Volume)	Extremely high (can be integrated with multi-function)
Deep Hole Drilling Cold Plate	Precision drilling of solid metal blocks	Extremely high (custom 3D path)	Extremely High (Extreme Performance)	Highest (pure integration)	High Cost/Unit (Low Volume)	Low (mainly runner)
Brazed/Bonded Fin Cold Plate	Fins brazed/bonded to the base plate and then sealed	High (high surface area fins)	High (excellent heat transfer efficiency)	High (brazing is better)	Medium Cost/Unit (Medium to High Volume)	Medium (simple functions can be integrated)
FSW Plate (Friction Stir Welding Cold Plate)	CNC machined by runners following of friction stir welding	High (complex 2D/3D)	High (stable thermal contact)	Very High (solid-state weld is excellent pressure resistance)	Medium (Medium to High Volume)	High (suitable for large scale structural integrated)
Extruded Cold Plate	Metal profiles are extruded and formed	Low (simple straight passage)	Medium-low (basic cooling)	High (Integrated Profile)	Very low cost/unit (very high volume)	Low (basic profile)

Winshare Surface Treatment & Finishing: Enhancing Customization and Batch Quality

Die-cast cold plates typically have a good surface finish, but further surface treatment and finishing can significantly improve their corrosion resistance, wear resistance, insulation, or aesthetics in specific application scenarios. Winshare offers a variety of professional surface treatment solutions to meet your customization needs and ensure consistency and high quality of bulk products.

Anodizing

Forms a dense oxide film on the surface of aluminum alloys, significantly improving corrosion resistance, hardness, and insulation, and can be colored to enhance aesthetics, meeting customized appearance needs.

Electroless Nickel Plating

A layer of nickel-phosphorus alloy is uniformly deposited on the metal surface, providing excellent corrosion resistance and wear resistance, suitable for fluid environments with high corrosion protection requirements, ensuring the long-term reliability of batch products.

Passivation

Chemical treatment of stainless steel or certain aluminum alloys to remove surface impurities and form a passivation film that enhances its inherent corrosion resistance, suitable for batch applications in specific environments.

Sandblasting/Painting

Used to improve surface roughness or provide additional protective layers and colors, suitable for applications with special requirements for appearance, and for the individualization of bulk products.

In addition to surface treatment, we also offer high-precision CNC finishing services to ensure the flatness of the contact surfaces between cold plates and heat sources, as well as the accuracy of critical dimensions such as interfaces and mounting holes, ensuring optimal thermal contact and system integration, and providing superior precision assurance for your bulk products.

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Winshare Die Casting Cold Plate Customization & Mass Production Process

Customized needs assessment and conceptual design

Gain insight into your heat load, size, fluids, costs, and volume production needs to develop a preliminary product concept and custom design direction together.

Precision mold design and simulation

Based on custom product design, perform precision mold design, and use casting simulation software (such as MAGMA) to optimize runners and pouring systems to predict and eliminate potential defects to ensure the quality and efficiency of mass production.

Efficient die-casting molding and preliminary processing

Efficient molding on advanced die casting equipment enables one-time rapid production of customized structures. Subsequently, preliminary processing such as deburring and water port removal is carried out to obtain cold plate blanks.

Precision machining and cleaning

High-precision CNC machining is performed on key dimensions and contact surfaces to ensure flatness and fit accuracy, ensuring consistency in batch products. This is followed by high-pressure cleaning of the internal runner to remove residue.

Total quality inspection and surface treatment

Conduct comprehensive quality inspections such as X-ray inspection, air tightness testing, and dimensional testing to ensure the high quality of each batch of products. According to customized needs, anodizing, nickel plating and other surface treatments are carried out to improve product performance.

Mass production and on-time delivery

Under strict production management and quality control, start mass production, ensure product consistency, and deliver your orders on time to meet your market demand.

Winshare Die Cast Cold Plates Application Areas

Automotive electronics

Battery cooling plates, ECUs, power modules

Telecommunications

equipment 5G base stations, routers, network switches

Consumer electronics

High-performance PCs, game consoles, projectors

Industrial control

Industrial PCs, drives, automation equipment

LED lighting

High power LED lamps, outdoor lighting

Medical devices

Diagnostic equipment, laboratory instruments

Winshare Die Cast Cold Plate Advantages Features

Customized Complex Structure Integrated Molding

Through precision molding, one-time molding of customized complex internal runners and external integration functions, greatly simplifying assembly and reducing overall manufacturing costs.

Cost-effective and mass production

Extremely high production efficiency and automation, demonstrating excellent cost advantages in high-volume production, ideal for high-volume projects.

Superior Mold Design and Batch Casting Capabilities

Professional mold design and casting simulation team to ensure efficient batch implementation of complex runners and structures, and ensure product consistency.

Reliable structural integrity and batch stability

One-piece molding without welds provides excellent air tightness and structural strength, reducing the risk of leakage and ensuring the stability of long-term operation of batch products.

Diverse material options to meet customization needs

Supports aluminum alloys, zinc alloys, magnesium alloys, and more, catering to the customized needs for performance and weight for different applications.

High-quality surface treatment and finishing to improve batch quality

Offering a variety of surface treatments and high-precision machining to enhance product functionality and appearance, ensuring the superior quality of bulk products.

Winshare Die Casting Cold Plate FAQ

Q What is the heat dissipation performance of die-cast cold plates?

A The heat dissipation properties of die cast cold plates are suitable for low to medium to high heat load applications. While its internal runner complexity may not be as complex as that of a brazed fin cold plate, it can still provide an efficient cooling solution with optimized runner design and high thermal conductivity, especially in terms of cost and volume production.
Q Are there any risks of porosity or internal defects in die casting cold plates?

A The die casting process does have potential risks of porosity. However, Winshare is able to minimize or even eliminate internal defects through precise mold design, strict process parameter control, and advanced X-ray inspection technology, ensuring product batch quality and reliability.
Q What is the mold development cycle and cost of die casting cold plate?

A Mold development is a critical part of the initial investment in die casting cold plates, with a cycle time of typically 4-8 weeks, depending on the complexity of the mold. However, once the mold development is completed, the subsequent mass production cost will be very low, and for high-volume projects, the initial investment can be quickly diluted.
Q What complex shapes and functions can die cast cold plates achieve?

A The die casting process offers a high degree of freedom in complex geometries and functional integration. In addition to the complex flow channels inside, we can directly integrate various functions such as mounting points, threaded holes, manifolds, sensor cavities, etc., which greatly reduces the complexity of post-processing and assembly, very suitable for customization and batch integration needs.

Contact us today to customize your cooling solution.

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