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Custom Heatsinks

jcdammeyer

jcdammeyer

John
Premium Member
I need 25 of these and due to the backlash from my ACME screws on the mill I really can't do this type of work yet. I can supply a STEP file or even the GibbsCAM file that the original machine shop used. Unfortunately the machine shop is closed because he retired. He did the last batch for me even though he was retired. Alas last summer he passed.

Although the drawings don't show it he actually machined them more like this but with less of a step. Done in levels so the thinner sections milled first and then the slightly thicker ones.
Heatsink-Rev3.jpg
AnodizedHeatsink.jpg


I have a video of the HAAS doing part of this. Unfortunately never did record the entire milling sequence but he did give me some lessons on what to do between sections to ensure the part didn't pull out of the vise.
 

Attachments

kstrauss said:
Rev 1.2 or 2.0? Are the steps on the fins essential? 6061? Who does the anodize?
Click to expand...
Apparently trying to cut the fins full depth in one pass results in broken fins or tool. Doing it in two levels results in less errors. Plus the cutting length of a 3mm end mill is shorter than the depth of the fins which is another reason to do it in two levels with a tad bit of clearance.

I have the entire GibbsCAM file but my eval time ran out this summer so I can no longer read them but it did show his approach.
I created the 2.0 to allow a bit more room for doing it on my mill. But Rev 1.2 preferably if it can be done.

In order to avoid hand work Rick also chamfered all the edges with I think a 45 degree mill. Raw stock is 1" x 1.5" 6061 I picked up at metal supermarket.

Anodizing is done in Richmond with the parts dropped off or picked up on the way back and forth from the circuit board assemblers.

My mill has too much backlash and vibration at 3000 RPM max spindle speed to do this. At least I think so. But I haven't tried to make this myself.

I have 11 anodized ones here and two not anodized so I can provide a sample as a guide to work from. In reality for this order I only need 12 but it's not worth the work for less than 25 pieces.
 
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jcdammeyer said:
Apparently trying to cut the fins full depth in one pass results in broken fins or tool. Doing it in two levels results in less errors. Plus the cutting length of a 3mm end mill is shorter than the depth of the fins which is another reason to do it in two levels with a tad bit of clearance.

I have the entire GibbsCAM file but my eval time ran out this summer so I can no longer read them but it did show his approach.
I created the 2.0 to allow a bit more room for doing it on my mill. But Rev 1.2 preferably if it can be done.

In order to avoid hand work Rick also chamfered all the edges with I think a 45 degree mill. Raw stock is 1" x 1.5" 6061 I picked up at metal supermarket.

Anodizing is done in Richmond with the parts dropped off or picked up on the way back and forth from the circuit board assemblers.

My mill has too much backlash and vibration at 3000 RPM max spindle speed to do this. At least I think so. But I haven't tried to make this myself.

I have 11 anodized ones here and two not anodized so I can provide a sample as a guide to work from. In reality for this order I only need 12 but it's not worth the work for less than 25 pieces.
Click to expand...
I don't usually do paying jobs but I'm bored... What do you anticipate for cost for 25 (unanodized) and how soon do you need them?
 
kstrauss said:
I don't usually do paying jobs but I'm bored... What do you anticipate for cost for 25 (unanodized) and how soon do you need them?
Click to expand...
I haven't received an order yet. Just a request for a delivery date. Since I no longer have an experienced supplier I can't just say January 30th. In fact I haven't even checked to see if any of the parts are an issue. During COVID I really had to jump through hoops to make the units.

Ends up looking like this:
1730068231854.png


Waiting for heat sinks and the custom boxes. I have 3D printed covers that go over everything during conformal coating.

1730068294108.png


And then they are ready to go into the boxes.
1730068337966.png


I'd have to dig out an old invoice but I think they were $30 each.
Do you want to try making one? Do you need the sample? Where are you located?
 
During Covid we had to go to some great lengths to get the Delphi pins for our connectors. Out boards were for an rp2040 to run remote heat for our gen heat units. The heat sinks I had were 205x205x60mm. For the scrs to run the heat cycle, using crydom scars. Was a good job but things got slow so I moved on. On that job got used to designing with surface mount. I won’t go back to through hole. So much easier.
 
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