Hybrid heatsinks combine the thermal conductivity of copper with the advantages of aluminium

Copper and cold sprayed hybrid-heat sinks have almost identical thermal results and outperformed the aluminum heat sink in a substantial fashion, thus showing the importance of quick heat spreading along the base. At the same time, the hybrid-heat sink weighed less than the copper heat sink.
Indeed, hybrid-heat sinks manufactured by cold spraying have higher production cost than commercially available aluminum heat sinks; however, adding a layer of copper on an aluminum heat sink decreases its thermal resistance by 48%. This has a direct effect on the production costs since the semiconductor area can be decreased by 94%. Besides, the deposition efficiency and deposition rates of copper powder by the cold spray process are 95% (including overspray) and 10 kg/h, respectively, indicating the potential of the CS-process to realize a cost-effective large-scale industrial production.


For detailled technical information, you can download the press release about cold sprayed hybrid heatsinks here.

    Cold sprayed hybrid heat sinks have excellent mechanical and physical properties
  • Electrical conductivity IACS up to 98%
  • Deposition efficiency > 98 %
  • Porosity < 0.5 %
  • Feed rate 10 kg/h
  • Hardness – 107 HV
  • Ultimate tensile strength – 285 MPa
  • Thermal conductivity 368 W/mK
  • Gas tightness < 1 × 10-7 mbar-l/s
  • Elongation 25%
  • Minimum layer thickness < 50 µm
  • Maximum layer thickness - no limit
Different kinds of cold sprayed ihybrid heatsinks

Different types of cold sprayed hybrid heatsinks

Setup of cold spraying hybrid heatsinks with copper

Setup of cold spraying hybrid heatsinks


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