High Pressure Die Casting is a cost effective option for high volume solutions required to be light weight and superior cosmetic surface quality. Die Cast heat sinks come out in near net shape and require little to no additional assembly and can range in complexity. Die cast heat sinks are popular in the LED market due to the unique shape and weight requirements and high volume production needs.
For high volume parts that require higher thermal conductivity, Aavid, Thermal Division of Boyd Corporation also has the capability for High Density Die Casting. This process also allows for the addition of embedded technologies.