This is a Server Heatsink Copper Embedded unit produced by BQUQ, a precision manufacturing factory in Dongguan, China. The copper core is press-fit and CNC-machined into the aluminum base to maximize
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This is a Server Heatsink Copper Embedded unit produced by BQUQ, a precision manufacturing factory in Dongguan, China. The copper core is press-fit and CNC-machined into the aluminum base to maximize
This is a Server Heatsink Copper Embedded unit produced by BQUQ, a precision manufacturing factory in Dongguan, China. The copper core is press-fit and CNC-machined into the aluminum base to maximize thermal conductivity where it matters, with a flatness tolerance of 0.01 mm and a runout of less than 0.02 mm. You get a lead time of 15 days for standard sizes, and we hold a copper hardness of 80 HRB to ensure the insert does not deform under clamp pressure.
Copper conducts heat at 401 W/m·K, which is 1.6 times better than aluminum's 237 W/m·K. But copper is heavy and expensive. Our design uses a copper slug embedded into the aluminum fin stack, giving you the hot-spot cooling performance of copper where the CPU contacts, while keeping the overall weight and cost of an aluminum heatsink. The copper insert is machined to a tolerance of ±0.01 mm and then press-fitted into a pocket with an interference fit of 0.02 to 0.03 mm. This creates a metal-to-metal bond that does not rely on thermal paste, reducing thermal resistance by up to 30% compared to a standard clip-on copper base.
We machine the base plate and the copper insert on the same CNC setup, using a vacuum fixture to eliminate vibration. The critical surface—where the copper meets the CPU—is finished with a fly cutter at 3,000 RPM, giving a surface finish of Ra 0.4 µm. The mating face between the copper and aluminum is held to a flatness of 0.01 mm across the entire 60 mm width. For the fin stack, we use a 4-flute carbide end mill with a 0.5 mm corner radius. The tool path is climb-milled at a feed rate of 1,200 mm/min to avoid burrs on the fin edges. Runout on the finished part is measured on a CMM with a tolerance of less than 0.02 mm, which ensures the heatsink sits perfectly flat on the server processor without rocking. For tool selection details, refer to our CNC cutting tool selection guide.
The copper insert is not soldered or glued. We use a controlled press-fit where the copper slug is cooled to -20°C and pressed into a heated aluminum pocket. This creates a mechanical lock that withstands 150°C thermal cycling without loosening. The interference is calculated based on the coefficient of thermal expansion: aluminum expands 23 µm/m·K, copper expands 17 µm/m·K, so the fit tightens as temperature rises. If you need even higher thermal transfer, we can apply a layer of indium foil (0.05 mm thick) between the copper and aluminum before pressing. This adds 0.2°C/W improvement. We also offer a nickel-plated copper option (3 µm thickness) to prevent oxidation in high-humidity server rooms.
The base is made from 6061-T6 aluminum, which has a yield strength of 276 MPa and a thermal conductivity of 167 W/m·K. The copper insert is C11000 (electrolytic tough pitch copper) with a purity of 99.9% and a hardness of 80 HRB. We do not anneal the copper after machining because that would soften it. Instead, we use a controlled stress-relief cycle at 180°C for 2 hours to remove machining stress without reducing hardness. The aluminum is heat-treated to T6 condition before machining. We can also use 6063-T5 for the fins if you need a lighter assembly, but the base stays 6061-T6. All raw material is sourced from ISO 9001 certified mills, and we include a mill test certificate with every shipment. If your design requires a different copper alloy, such as C18200 (chromium copper) for higher strength, we can machine that as well.
Every Server Heatsink Copper Embedded is inspected on a Zeiss CMM. We check 12 critical dimensions: the base flatness, the copper insert height relative to the aluminum surface, the fin pitch, and the overall runout. The copper insert height is held to +0.00/-0.05 mm relative to the base, meaning it sits flush or slightly recessed. We also perform a thermal resistance test on a sample from each batch: we mount a 100 W heater to the base and measure the temperature rise at a 1.5 m/s airflow. The result must be within 5% of the design spec. For visual inspection, we use a 10x magnifier to check for burrs on the fin edges and a surface roughness tester to confirm Ra 0.4 µm on the base. We do not use pass/fail gauges only; we record the actual measured values in a PDF report that ships with the parts. The report includes the CMM data, material batch numbers, and the operator's sign-off.
| Specification | Value | Unit / Notes |
|---|---|---|
| Base Material | 6061-T6 Aluminum | Yield 276 MPa |
| Copper Insert Material | C11000 (99.9% Cu) | Hardness 80 HRB |
| Base Size Range | 50 x 50 mm to 200 x 200 mm | Custom sizes available |
| Fin Thickness | 0.8 – 2.0 mm | CNC machined, not skived |
| Fin Pitch | 2.0 – 4.0 mm | As per drawing |
| Flatness Tolerance (Base) | 0.01 mm | CMM verified |
| Runout (Overall) | < 0.02 mm | Per datum A |
| Surface Finish (Base) | Ra 0.4 µm | Fly cut finish |
| Copper Insert Height Tolerance | +0.00 / -0.05 mm | Flush to recessed |
| Lead Time (Standard) | 15 days | After drawing approval |
| MOQ | No MOQ | 1 piece accepted |
For the aluminum fins, we recommend a black anodize (Type II, 18 µm thickness) which increases emissivity to 0.85, improving radiation heat transfer in a server rack. The anodize is applied after machining, and we mask the copper insert to keep it bare for maximum conductivity. If you need a uniform appearance, we can nickel-plate the entire assembly, but this adds 0.5°C/W thermal resistance. For coastal or high-humidity environments, we apply a clear chromate conversion coating on the aluminum and a benzotriazole-based anti-tarnish dip on the copper. We do not use painted coatings because they act as insulators. The plating thickness is controlled to ±10% and measured with a magnetic gauge. All finishes are RoHS compliant and tested for salt spray resistance per ASTM B117 (minimum 48 hours).
Our factory has 24 CNC machining centers dedicated to heat sink production. The tooling for the copper insert and the aluminum base are standardized: we use a 10 mm indexable end mill for the base and a 6 mm carbide end mill for the fin slots. This means we do not need to wait for custom tooling for most designs. We stock 6061-T6 aluminum plates in thicknesses from 10 mm to 40 mm, and C11000 copper round bars in diameters from 20 mm to 80 mm. For a standard Server Heatsink Copper Embedded with a 60 x 60 mm base, the machining cycle time is 8 minutes. We run two shifts, so we can process 100 units per day per machine. Your parts are inspected on the same day they are machined, and we ship via DHL Express or FedEx. If you need an even faster turnaround, we offer a 7-day express service for an additional 20% surcharge. The key is that we do not re-invent the process for each order—we use proven parameters from our CNC machining tolerances guide to set up the job.
Heat sinks for servers are sensitive to electrostatic discharge and physical damage. We pack each unit in an anti-static foam tray (surface resistance 10^6 to 10^9 ohms) and then place it in a corrugated box with a 5 mm foam lining. The copper insert is covered with a removable PE film to prevent scratches during shipping. We do not use loose fill or plastic wrap that could generate static. Each box is labeled with the part number, batch number, and a barcode. For large orders, we use wooden pallets with a 4-way entry base, and we seal them with stretch film. The packaging is designed to survive a 1.2-meter drop test without damage to the fins or the copper insert. We also include a desiccant packet (5 g) to absorb moisture during air freight. If your parts are going into a cleanroom, we can double-bag them in ESD-safe bags with a vacuum seal.
We have no MOQ—you can order a single prototype or a full production run, and the unit price is the same for 1 piece or 100 pieces.
Yes, we machine the copper insert to your exact drawing, including stepped profiles, multiple copper slugs, or a full copper base plate, with the same 0.01 mm tolerance.
Every unit, prototype or production, goes through the same CMM inspection and thermal resistance test, and you receive the full inspection report with the shipment.
Standard designs ship in 15 days; custom designs with new drawings take 18-20 days because we need to program the tool paths and order any non-standard raw material.
Send us your drawing in STEP, IGES, or PDF format. We will review the geometry, confirm the material, and give you a firm unit price and lead time within 12 hours. If you need a recommendation, we can suggest a standard size that meets your thermal budget. We are a precision manufacturing company made in China with 20 years of CNC machining experience. No MOQ, no upfront tooling fees for standard sizes. Email your drawing to sc@bquq.com or reach us on WhatsApp at +86 13713157787. We reply within one business hour during China working hours (8:00-18:00 GMT+8).
| Parameter | Capability |
|---|---|
| Materials | AL6063/6061/5052, pure copper C1100, copper-aluminum composite |
| Process | Extrusion, CNC machining, skiving, forging, die casting, stamping fins |
| Fin Types | Extruded, pin fin, skived, folded, bonded, heat pipe, vapor chamber |
| Surface | Black anodizing, clear anodizing, nickel plating, powder coating |
| Size Range | Max 1500 x 400 x 300 mm |
| Thermal Test | Thermal resistance and heat dissipation data per batch |
| Prototype | 5-7 days, no MOQ on samples |
| Inspection | CMM, thermal resistance tester, full report per batch |
