| Summary: | The increasing popularity of electric vehicles has increased the demand for lightweight auto parts. However, the excessive weight of traditional metal heat sinks has remained a concern. Metal has excellent thermal conductivity but low radiation efficiency. Conversely, thermoplastic polymers have excellent heat radiation efficiency but poor thermal conductivity. In this study, we propose a radiator constructed using thermoplastic polymer and insert-molded aluminum alloy parts to maintain the low junction temperature of light-emitting diodes (LEDs); the radiator’s weight is reduced through a combination of aluminum alloy and a thermally conductive polymer designed for automotive headlights. At an LED thermal load of 11.48 W, the measured temperature on the LED pad is 60.8 °C. The weight of the proposed radiator is 23.37% lighter than that of a pure metal radiator. When the lightweight radiator is used in high-power LED headlights, it effectively dissipates heat within a limited space.
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