Consumer Electronics Stamped Heat Sink: High-Volume Progressive Stamping, 1M pcs/Month, Black Anodized
Heat sinks in LED lamps, power adapters and small appliances are classic "cheap but huge-volume" parts: a few cents each, millions a year per program. Extrusion tooling does not pay back at this size and CNC is out of the question - the right answer is stamping: an aluminum strip running through a progressive die punches the profile, bends and locating holes at dozens of parts per minute.
Project Background & Challenge
A lighting and power supply maker was sourcing a heat sink for a bulb driver: 1060 aluminum, 1.2mm thick, profile with bends and two locating holes, black anodized, 10 million pieces a year, and a tight target piece price. The previous supplier used laser cutting plus hand bending - slow, expensive, and bend angles wandered.
The challenges: the stamping layout has to fold blanking, bending and piercing into one die with accurate springback compensation; high volume means die life and predictable resharpening cycles; and anodizing is outsourced, so color consistency and schedule risk need active management.
BQUQ Process Solution
Progressive Die, One Pass
An 8-station progressive die blanks, bends, pierces and sizes in one pass, with bend angles pre-set from springback compensation. Die sections are wear-resistant alloy tool steel designed for 5 million strokes, with resharpening scheduled at 1 million strokes to minimize downtime.
Surface & Packaging
Black anodizing runs with a qualified partner under per-batch coating thickness and color sampling. Parts are packed in trays with anti-scuff protection. Dimensional and appearance reports ship with every batch.
Key Specifications
| Item | Specification |
|---|---|
| Material | 1060/5052 aluminum (per drawing) |
| Stock thickness | 0.8-2.0mm |
| Bend angle | ±1°, formed in the die |
| Surface | Black anodizing, thickness measured per batch |
| Die life | Designed for 5M strokes |
| Volume | 1M pcs/month, 10M/year class |
| Inspection | Bend/dimension sampling + coating thickness & color |
Quality Control & Delivery
Bend parameters are locked after tryout; per-batch first articles are fully checked with key dimensions sampled every two hours. Anodizing batches are compared against color standards. A 100,000-piece pilot ships in 12 days, then rolls at one million a month with piece cost more than 30% below the previous process.
Related Products & Resources
To see more parts in this category and how we scale them, browse the Stamped Heat Sinks category page, or these related products:
Related Q&A: What Are the Best Thermal Management Strategies for Optical Modules in AI Networks? More Q&A is in our FAQ Center.
For our capabilities, equipment and quality system, visit About BQUQ and Factory Strength.
FAQ
How much cheaper is stamping than laser cutting?
At volume, usually 30% or more - better material utilization, faster cycle time, fewer operators. The exact number depends on the drawing; send it over and we will price it both ways.
How do you control bending springback?
The die pre-overbends from springback compensation, tryout tunes it from measured parts and locks it; in-process bend sampling catches drift before it becomes a bad batch.
Can you hold a 1M pcs/month schedule?
Yes. High press speed, long die life and scheduled resharpening at 1M strokes, plus backup die management - million-piece months are routine on this line.
