Optical Module Housings and Thermal Blocks

Requirement

The customer’s optical modules need an aluminum housing for the internals, with a thermal block carrying heat to the shell. Parts are small and thin-walled with tight tolerances, the block must combine copper conductivity with machinable aluminum, and volume is high enough that every batch must match.

Our approach

Housings are machined as small CNC parts with multi-part fixtures for throughput and consistency; thin walls are roughed then finished with symmetric stock removal to limit movement. The block is a copper-aluminium laminate: copper against the device, aluminium against the housing, with the joint face checked for flatness. One fixture and one inspection template for the whole batch.

Delivery and inspection

First batch of 200 sets with key dimension sampling and joint-face flatness records; tray-packed to prevent mixing.

Project summary

Batch consistency held and module shell temperature met the customer test plan. The multi-part fixture cut unit time, and later models kept the same process.