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general heat sink rules for fin dimensions

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coppercone2:
Is there a general rule for manufacturing heat sinks that can be followed, or restrictions?

The idea is to get copper or aluminum block and use the smallest endmill possible as long as possible which my little mill can handle in order to manufacture a heat sink.

From what I have seen in CPU coolers, you can basically go to playing card thickness on fins ?

The smallest endmill I have is 0.8mm. Assuming it does not break, and I have the will to sit there and make this very slowly, is there any reason to go to a higher mill size?

Also, is it optimal to have the same dimension for the spacing between the pin as the pin itself ?

Main concern is that I feel the endmill may break. I want to know if its the best to use 0.8mm or if I am actually hampering myself and taking additional risk (Which I will take even for small benefit, but IS there a benefit?)

Black Phoenix:
This read must be interesting for your proposes.

https://www.fictiv.com/hwg/design/heat-sink-design-guide

Another one in PDF format from Digikey:

https://www.digikey.com/Site/Global/Layouts/DownloadPdf.ashx?pdfUrl=F51974C9A6D544F1A7D8F119514B67FF

coppercone2:
Ok, do you have thermal simulations for the same heat sink with different spacings?

If I am doing forced air, I am thinking air condition manufacturers some how tuned this over the years. They use something like 1mm spacing, so all I would need to do is determine the flow required through those plates?

I wonder if they optimized it?

The document is a bit much, I feel like I am getting another degree to manufacture a single component.

though , this is good

coppercone2:
why don't room air conditioners follow those guidelines though?

they use like 0.007 thick 0.07 spacing with heavy forced air.
https://www.powerelectronics.com/content/optimize-fin-spacing-how-close-too-close

coppercone2:
https://myheatsinks.com/calculate/plate-fin-heat-sink-calculator/

maybe I can get a feel for it by doing 10 common heat sink sizes with a bunch of iterations in each and making a flip book with graphs

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