This method is highly versatile, as manufacturers can create the exact shape they need. Typically, heat sink material is poured into a die designed for a certain cross section. The die then forms a shape resembling the desired shape. Extruded heat sinks can be molded to fit various shapes, and they also come in a variety of colors. However, color does not affect the performance of an extruded heatsink.

The type of fins used in an extruded heatsink can vary in shape, material, and design. They may be flat, flared, or crosscut. They offer a high surface area and are excellent for applications where airflow is adequate. Because of their low-pressure-drop features, these aluminium extrusion heat sink  are usually combined with a base for better performance. The most common material used in extruded heat sinks is aluminum.

Extruded heat sinks can have various surface coatings. The most appropriate choice for your specific application depends on the material used. For example, powder coating uses an electric charge to trigger a dry powder to fuse with the material. Anodizing, on the other hand, uses an electrochemical process to create a corrosion-resistant, resilient oxide finish. Nickel and chrome plating both have outstanding solderability and dimensional repeatability.

Copper is another good choice for extruded heatsinks. It is an excellent conductor of heat. However, copper is extremely heavy and limiting to extruded heat sinks. Copper is also more expensive than aluminum, but is more durable and lightweight. Copper-based extrusion heatsinks can be extremely complex and expensive. Copper heat sinks are typically larger and thicker than their aluminum counterparts.

Aluminum extrusion process markets typically run smaller extrusion runs to meet customer demands for lower quantities. Additionally, because smaller parts have low shipping costs, extrusion is a viable option for manufacturers of extruded heatsinks. This manufacturing method is also less expensive than CNC machining and post-machining. Further, extruded heatsinks provide thin fins and optimal heatsink performance.

Extruded heat sinks are popular in industrial and commercial workstations, as well as audio equipment. They are even used in the medical industry, where temperature control is essential to maintaining the health of patients. In addition, they are common in computer hardware, including graphics cards, processors, and other devices. In addition to computers, they are also used in audio appliances, such as recording studios. These devices need to operate at an appropriate temperature to maintain their functions.

Extruded heat sinks are commonly made of aluminum, a versatile material that offers cost-effective performance and durability. Different types of aluminum alloys have different characteristics, but the 6000-aluminum series is the most common and economical choice for many users. Its thermal conductivity is 166-201 W/mK. Another type, aluminum 1050, is very strong but mechanically soft. Aside from alloy, custom colors can also affect the heat sink's performance.