Heat Sink Calculator

Size the heat sink you need, or find the junction temperature of a power device from its thermal chain.
Required Heat Sink
Junction Temperature

Required Heat Sink Thermal Resistance

θSA = (TJ(max) − TA) / Pdiss − θJC − θCS
10W, TO-220
25W MOSFET
5W, hot ambient
W
°C
°C
°C/W
°C/W
Enter values and press Calculate.

Junction Temperature for a Given Heat Sink

TJ = TA + Pdiss × (θJC + θCS + θSA)
10W + 5°C/W sink
10W, no heat sink (~60°C/W)
W
°C
°C/W
°C/W
°C/W
Enter values and press Calculate.

The Thermal Resistance Chain

Heat flows from the silicon junction → device case → heat sink → ambient air. Each step has a thermal resistance in °C/W, and they add up in series like electrical resistors. The temperature rise above ambient equals the power dissipated times the total thermal resistance.

SymbolMeaning
θJCJunction-to-case (from the device datasheet)
θCSCase-to-sink (thermal pad / paste, ~0.2–1 °C/W)
θSASink-to-ambient (the heat sink's rating)
TJTA + P × (θJC+θCS+θSA)

A lower θSA means a bigger/better heat sink. If the required θSA comes out negative, no heat sink can keep the part cool — you must reduce power, lower ambient, or pick a device with lower θJC.

Real-World Applications

Worked example

A MOSFET dissipates 8 W with θJC = 1 °C/W and a 0.5 °C/W pad, in a 40 °C enclosure, and must stay below TJ = 125 °C.
Allowed total θJA = (125 − 40)/8 = 10.6 °C/W, so the heat sink must be θSA ≤ 10.6 − 1 − 0.5 = 9.1 °C/W or lower — a modest clip-on or small extruded sink meets this.

FAQ

Do I really need thermal paste?

Yes for anything above a watt or two. Paste (or a pad) fills microscopic air gaps between the case and sink, dropping θCS from ~1 °C/W dry to ~0.2–0.5 °C/W.

Natural convection or a fan?

Still-air heat sinks are quiet and reliable. Adding a fan (forced convection) can cut the effective θSA by 2–4×, letting a smaller sink handle the same power — useful when space is tight.

How does heat sink size relate to θSA?

More surface area and fins mean a lower θSA (better cooling). Datasheets rate sinks in °C/W — pick one at or below the value this calculator gives.

Can several devices share one heat sink?

Yes, but their heat adds up. Sum the power dissipations for the θSA calculation, and remember each device still has its own θJC and pad in series with the shared sink.

Do I even need a heat sink?

Compute the junction temp with no sink (θSA very large). If TJ stays below the maximum with margin, you don't. Otherwise size one with the first tab.

What is a typical θCS?

Dry metal-to-metal ≈ 0.5 °C/W; with thermal paste ≈ 0.2–0.4 °C/W; with an insulating mica/silicone pad ≈ 0.5–1.2 °C/W.

How much design margin should I leave?

Keep TJ at least 20–30 °C below the datasheet maximum for reliability and to allow for hot days and aging.

Frequently Asked Questions

How do I calculate the heatsink thermal resistance I need?

Rearrange Tj = Ta + P(θJC+θCS+θSA). The heatsink must provide θSA ≤ (Tj(max) − Ta)/P − θJC − θCS, and designing to about 80% of Tj(max) leaves sensible margin.

What is θCS and why does it matter?

The case-to-sink thermal resistance, set by the mounting interface. A dry joint can add several °C/W; thermal compound or a gap pad typically brings it to a few tenths. On low-power parts it is negligible, but on a device dissipating tens of watts it can dominate.

Should I use the θJA figure from the datasheet?

Only for a rough estimate. θJA assumes a specific test board in still air and rarely matches a real installation. For heatsink design, use θJC and add the interface and heatsink resistances yourself.

How much does forced air help?

A great deal — natural convection heatsink ratings often improve by a factor of two to four with modest airflow. The figure quoted on a heatsink datasheet is usually for natural convection unless airflow is stated.

What ambient temperature should I design for?

The air immediately around the heatsink, not room temperature. Inside a sealed enclosure that is commonly 15–30 °C above the room, and using room temperature instead is a frequent cause of thermal failure.

Does heatsink orientation matter?

Yes, for natural convection. Fins must run vertically so warm air can rise between them. A heatsink mounted with horizontal fins can lose a substantial fraction of its rated performance.

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