High-Brightness LED Heat Sink

This aftermarket application is a good example of replacing die-cast aluminum with injection-molded conductive thermoplastic on heat sinks for high-brightness (HB) LED transportation lamps.  LED lighting is becoming increasingly popular because it uses less energy but provides drivers with greater visibility and longer use life than standard halogen bulbs. However, as heat builds up, LED lighting performance and use life goes down, so the heat sink plays an important role in efficient operation of the lighting. A special grade of high-conductivity (20 W/m-K) PA 6/6 resin was developed for the application, which reduced weight 39% and costs 20% vs. the die-cast aluminum it replaced.  Interestingly, only minor modifications were required to reuse the aluminum die-cast tool to make it suitable for injection molding of the thermoplastic solution. And the customer now molds heat sinks in-house, simplifying logistics, reducing delays, freeing capital, and allowing the company to better capture the value of its products.

OEM/Vehicle Aftermarket 2014  System Supplier Ayfar Otomotiv Material Processor Mars Otomotiv

Material Supplier PolyOne Corp. Resin Therma-Tech TT6600-5001EC Thermally conductive PA Tooling/Equipment Supplier Mars Otomotiv

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