Aluminum Heat Sink Fin Spacing: Why More Fins Often Cool Less
Why the air gap matters more than the metal In extrusion heat sink work, the dimension that separates a good profile from a disappointing one is usually the channel width between fins. A broader heat sink profile guide can help frame the alloy and finish choices, but the real thermal swing often comes from how much room the air has to move. A heat sink is not a pile of aluminum that happens to get hot. It is an air-handling device with aluminum attached. Once the die is cut, the fin pitch is fixed, so the spacing becomes a design decision with manufacturing consequences. Get it wrong and the profile can look aggressive on paper while performing worse than a simpler shape with fewer fins. ...