Hi-Rel manufactures make-to-print heat spreaders and thermal tabs for hermetic RF packages, power amplifiers, laser mounts, and submount applications, with material options matched to your CTE and thermal performance requirements. For demanding designs, our proprietary processing supports complex geometries and tight flatness specifications that conventional stamping cannot hold.
Expertise Through Strategic Partnerships & Proprietary Thermal Optimization Processes
Our leadership in thermal management manufacturing is strengthened not only by our technical capabilities, but also by the deep strategic partnerships we maintain across the semiconductor, medical, aerospace, RF, and defense industries. These collaborations give us unique insight into evolving design challenges, reliability requirements, and emerging thermal performance standards—enabling us to engineer components that consistently exceed customer expectations and industry benchmarks.
Proprietary Processes That Ensure Exceptional Flatness
Mission‑critical electronic devices demand precision surfaces that maximize thermal transfer efficiency. Our proprietary machining, cladding, and finishing processes are specifically engineered to deliver industry‑leading flatness and uniformity, even on large or complex thermal spreaders and heatsinks. This enhanced flatness minimizes thermal resistance, prevents hotspots, improves TIM (thermal interface material) contact, and ensures consistent, long‑term heat dissipation across the entire device footprint.
Lowest Voiding in the Industry for Maximum Thermal Performance
Through continuous innovation and tightly controlled manufacturing workflows, we achieve the lowest voiding levels in the industry, delivering the highest possible thermal conduction between layers and assembly interfaces. Lower voiding directly translates to:
- Superior heat transfer efficiency
- Greater reliability under high power loads
- Reduced thermal cycling stress
- Extended device lifespan
Our customers rely on this level of precision when designing power modules, semiconductor packages, and other advanced systems where thermal failures are not an option.
Material Options for Heat Spreaders
The right heat spreader material depends on the semiconductor, the power density, and the weight and inspection constraints of the package:
- DiaCool® diamond composites (silver, copper, and aluminum diamond) for the highest conductivity with a CTE matched to SiC, GaN, and GaAs. See Diamond Metal Matrix Composites.
- CVD Diamond for the most extreme power densities, up to 2000 W/m·K. See CVD Diamond.
- MoCu and WCu CuMoCu legacy composites for traditional RF housings, power modules, and moderate-to-high-power applications where predictable performance is essential. See Legacy Thermal Materials.
Our proprietary EDM-based mass-production process delivers the linear dimensional compliance and flatness that conventional stamping cannot match, producing some of the lowest voiding levels in the industry at the bond lines that matter most.
Industry‑Leading X‑Ray Results for Quality Assurance
We are committed to ensuring our customers achieve the highest quality products which promote industry leading structural integrity, bond uniformity, and void minimization across every critical interface. Our best‑in‑class X‑ray results confirm that each component meets the highest standards for thermal continuity and mechanical stability—ensuring flawless performance in demanding Hi‑Rel environments. This is essential for sectors where absolute reliability is mandatory, such as aerospace, defense electronics, medical instrumentation, and high‑power RF systems.
Fully Adaptable to Any Design or Thermal Architecture
Because every application presents unique thermal management challenges, our manufacturing processes and design expertise are built around complete adaptability. We support custom geometries, tailored stack‑ups, unique metallurgical combinations, and application‑specific design requirements, including:
- High‑power semiconductor substrates
- Complex RF and microwave packages
- Miniaturized MEMS architectures
- Multi‑layer thermal spreader assemblies
- Custom heatsinks for constrained environments
Whether you require a standard configuration or a fully engineered thermal solution, our team provides the engineering flexibility and manufacturing precision needed to support any design architecture or form factor.