Engine mounts, chassis parts, and machined components for assembly lines.
Thrust reverser latches, bolt carrier assemblies, and fasteners for aircraft and defense sector.
Connector housings, EMI shielding brackets and lightweight chassis for industrial electronics parts.
Precision housings, actuator frames, and armature linkages for automation systems.
Metal frames, brackets, and assemblies for appliances and home equipment.
Orthopedic implant screws, surgical drill guides and enclosures for sterile environments.
Solar mounting parts, wind turbine brackets, and battery enclosures.
Valve bodies, flange blocks, and downhole drilling components.
Rudders, propellers and corrosion-resistant components for offshore and deck-side systems.
CNC machining delivers micron precision and tight tolerances for complex geometry.
Optimized for mass production, high-volume machining utilizes advanced automation and process control to ensure consistent quality, tight tolerances, and superior cost efficiency at scale.
Designed for precision-driven applications, low-volume machining supports prototype development and limited production runs with high accuracy, rapid iteration, and reduced tooling requirements.
Driving LEDs at high current increases junction temperature. This lowers light output and shortens LED life. The LED Array Heat Spreader reduces total thermal resistance between the die and the heatsink. Thermal resistance can go below 0.15°C/W. This allows faster heat transfer and keeps junction temperatures within safe limits.
LED modules experience thermal expansion during on-off cycles. Different CTE values between PCB and housing create mechanical stress. The LED Array Heat Spreaders uses CTE-matched materials like Cu-Mo or AlSiC. These materials reduce stress at solder joints and prevent delamination. Long-term structural integrity is maintained even during frequent thermal cycling.
Some lighting designs limit airflow. Sealed or compact housings restrict convection-based cooling. The LED Array Heat Spreader improves thermal spreading without increasing system height. Thin spreaders—under 0.5 mm—enable two-dimensional heat flow. This helps maintain safe operating temperatures in low-ventilation environments.
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LED Array Heat Spreaders manage thermal gradients in compact linear modules used in recessed, wall-wash, and cove lighting applications.
Enables uniform thermal distribution in DRLs, headlamps, and signal assemblies operating under sealed, vibration-prone, and high ambient temperature conditions.
Maintains junction temperature uniformity across multi-emitter arrays in low-pressure, vibration-sensitive aircraft cabin illumination environments.
Controls emitter temperature in high-lux, thermally dense LED arrays used in continuous-operation, sterile-field medical lighting equipment.
Prevents hotspot formation in high-intensity strobe or backlight LED arrays critical for thermal consistency in optical inspection systems.
Supports thermal regulation of high-power COB modules operating at elevated heights with limited convective air movement.
High-lumen COB modules generate hotspots near central emitters. These zones face early lumen depreciation. The LED Array Heat Spreader draws heat away using embedded vapor cores or carbon layers. Surface temperature stays uniform. No single LED experiences excess thermal loading.
Contact resistance at TIM interfaces reduces thermal efficiency. Poor flatness creates thicker TIM layers and uneven heat flow. The LED Array Heat Spreader is machined to under 10 µm flatness. Surface roughness stays below Ra 0.8 µm. This reduces TIM thickness and improves thermal conductivity at both contact surfaces.
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Frigate maintains strict thermal conductivity control through raw material certification and process monitoring at each stage. Flatness, thickness, and bonding integrity are verified using non-contact metrology. Batch-level thermal resistance is validated using laser flash analysis. This ensures every LED Array Heat Spreader delivers consistent thermal behavior.
Frigate offers CTE-controlled materials ranging from 6 to 17 ppm/°C, suitable for alumina, aluminum nitride, or hybrid ceramic substrates. Materials like Cu-Mo and AlSiC are selected based on stack-up requirements. Custom spreaders are FEA-tested for thermo-mechanical reliability under thermal shock. This prevents substrate cracking or solder fatigue in cycling environments.
Frigate provides sub-10 µm flatness and <0.8 µm surface roughness across all critical interfaces. This minimizes the bond-line thickness of TIM or solder preforms. Nickel plating or Au flash finishing options are available for improved die attach compatibility. The result is a lower junction-to-ambient thermal path.
Yes, Frigate designs multilayer LED Array Heat Spreaders using stacked graphite sheets, phase-change cores, or copper foils. Layer orientation and thickness are tuned for directional thermal diffusion. This is particularly useful in asymmetrical emitter layouts or edge-mounted heat sink geometries. Thermal anisotropy is modeled using in-house FEA tools.
Frigate conducts environmental testing including 85°C/85% RH exposure, thermal cycling, and salt fog resistance. Spreaders are sealed with vapor barriers or coated for corrosion resistance. Material stack-ups are selected based on water vapor transmission rate (WVTR) data. This ensures long-term reliability in outdoor and sealed luminaire applications.
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10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.
9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ
FRIGATE is a B2B manufacturing company that facilitates New Product Development, contract manufacturing, parallel manufacturing, and more, leveraging its extensive partner networks.
Need reliable Machining for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
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