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Aluminum alloys are popular for extruding as heat sinks because they provide both malleability and formability. They can be easily machined and are as little as one-third the density of steel. This results in extrusions that are both strong and stable, at a reduced cost relative to other materials.
The aluminum extrusion process starts with designing and creating the die that will shape the heatsink extrusion. Once this has been done, a cylindrical billet of aluminum is heated up in a forge to high temperatures, generally between 800-925°F (427-496°C). Next, a lubricant is added to the aluminum to prevent it from sticking to any of the machinery. It is then placed on a loader and pressure is applied with a ram to push heated aluminum through the die.