Aluminum material vs Plastic material LED Channels : Which Dissipates Heat Better?

As you know,now the aluminum material cost increase a lot compare last year. Many customer ask us: " Can I just use plastic material boday instead of aluminum? Are the heat dissipation effects the same? " Today, we put aluminum material vs. plastic materail with real thermal data.

The Problem with Plastic

While they diffuse light well, they completely encase the LED strips with a material that has almost zero thermal conductivity.                            The heat generated by the chips has nowhere to dissipate but accumulates inside the channels, leading to:

Adhesive failure: 3M tape softens, causing the light strip to detach.

Light decay: The plastic casing yellows/becomes opaque.

Solder joint cracking: Overheating causes electrical connections to break.

The Aluminum Advantage

Aluminum is a natural heat sink.

Our LED aluminum channels (typically made of 6063-T5 aluminum alloy) work by conducting heat away from the LED strip and dissipating it through the channel walls and base. Even at high brightness (e.g., 20W/m), the aluminum surface keeps the internal temperature below 60°C (140°F), which is the upper limit of the safe operating temperature for most SMD LEDs.

Real Testing data

We conducted a simple test at our factory (room temperature: 25°C).

Test conditions: A 1-meter-long 24V COB LED strip (14W/m) running at 100% brightness for 60 minutes.

Plastic tube: Internal temperature reached 78°C (172°F). The strip began to flicker.

Our aluminum U-tube: Internal temperature stabilized at 52°C (125°F). The strip ran smoothly.

Conclusion: Reducing the operating temperature by 26°C can double the lifespan of an LED strip.

Ready to upgrade your project with reliable aluminum profiles?

We offer:

Free thermal calculations based on your LED power.

5-meter samples for your testing.

Custom anodized finishes (silver, black, white).