Thermal design is critical for power module reliability. This guide provides methods for calculating thermal requirements and selecting appropriate cooling solutions.

Power dissipation calculation: Pdiss = Pout × (1/η - 1). For example, 50W output at 90% efficiency dissipates 5.6W.

Temperature rise calculation: ΔT = Pdiss × Rth, where Rth is thermal resistance from junction to ambient.

Heatsink selection depends on maximum allowable temperature rise. Natural convection requires larger heatsinks than forced air.

Thermal management best practices: Keep power modules away from heat sources, ensure adequate airflow, use thermal interface material, and verify with thermal measurements.