A Cold forged heatsink is a good alternative to casting to form complex shapes with excellent thermal conductivity.The Cold forging process can make almost perfectly straight allowing for more fins per square mm.

Tech details

A Forged heatsink is manufactured using a modification of this process called cold forging. Cold forging uses high pressure and low temperature to ensure that no air bubbles, or other impurities are trapped in the material. This improves the thermal properties of the heatsink, and increases the density of the material.
Cold forged heatsink manufacture lends itself very well to using copper because high temperatures are not required to shape the copper heatsink, and it can be formed with minimal damage. Secondary machining operations such as hole, chamfer, and steps can be usually included in the cold forged heatsink manufacture reducing waste. Forging involves the shaping of metal using localized compressive forces.