Application Profile

Large Heat Sink and Lead

Cold formed burrless CDA 102 high conductivity copper heat sink and lead
Large Heat Sink and Lead 3D Rendering Large Heat Sink and Lead Technical Drawing
Use:  Diode Heat Sink & Terminal Lead.
Material:  CDA 102 oxygen free high conductivity copper.
Manufacturing Method: 
  • Produced from coiled wire.
  • Manufactured complete from cold forming machine-no secondaries.
  • Tooling designed & built in-house at Sussex Wire, Inc.



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Notable Features: 
  • This headed pin represents a large heat sink (ie: the head portion) and a small diameter terminal lead (ie: the long shaft) manufactured as a ONE PIECE design.
  • Surface finishes better than 32 rms.
  • Concentricity of major OD to minor OD is .002" TIR.
  • Burrless.
  • No machining lines or cut off deformations present.
  • This one piece design is meant to supplant the usual two piece brazed assembly. Normally a part like this would be manufactured by brazing the .050" diameter terminal lead onto a larger Heat Sink. Therefore this design eliminates the braze assembly and replaces it with a single one piece part.
  • Near perfect concentricity of terminal lead to major OD and very good thermal and electrical conductivity since there is no braze joint or weld on the part.
  • A variety of shapes can be formed for the Heat Sink portion, not just the cylindrical shape, using the same forming technology and production processes. The Heat Sink portion of the part could even be shaped as a cup rather than a solid cylinder.

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