Well, lots of good discussion here... I have one more question/observation that might help:
Are you really sure you want 1/8" slots 2" deep? I've designed a few heatsinks for electronics, and although I'm a bit busy to get the handbooks out right now about fin optimization, I'm pretty sure that unless you're forcing the air, a 2" high fin 1/8" wide with an 1/8" slot won't work really any better than a 1" high one owing to the boundary layer in the slot.
In other words, the air doesn't do a whole lot at the bottom, it's at the top where the action is. Hope this doesn't seem insulting, it's just that making a decent heatsink isn't a matter of "put mo' fins", the heat conduction capacity of the fins needs to balance out with the capacity of the air space to remove it. |