My Custom Laser Design

I've been thinking about making this  since I saw Daves 8X Burner. Of course I would like to make my own when I can afford it. I have a nice piece of titanium that I plan to use.
I have this green 20mW laser that I got from DX a while back(my favourite) and I really like its sturdiness and weight.
http://www.dealextreme.com/details.dx/sku.2511

So I came up with this laser module head design that is one peice that will press fit onto the body of the above-mentioned pointer.  Obviously it will require a Flexdrive to run off of a single CR2(maybe 2 in parellel for an 8X).  Also if I am going to use an 8X diode, I'll be needing one of those 405-G1 lens assemblies.

If I had my own lathe, I would make a whole bunch of them and then maybe I could make some money.

Anyway, everyone is free to use the design and of course change it any way they see fit for their own custom laser.
If this design is close to any one elses design I appologize in advance. I have never seen a custom laser, aside from the pictures on this forum.

Also, if there is anyone out there willing to do the machining for me, it would be great if you could make a deal with me.  I won`t have access to a lathe for a while.

Peace, Steve

P.S. Sorry about the Windows Paint cartoon drawing. That's all I have.

The problem with the LD being reccessed like that is it will be almost impossible to solder it to the driver board....Unless you solder flying leads to the LD before pressing it in..

Regards rog8811

You're exactly right Rog. That is what I had planned on.

I know titanium is a bitch to machine, but do you want to machine it for me?

I know titanium is a bitch to machine, but do you want to machine it for me?

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I don't have suitable tools for a lot of that, no Tap for the lens thread for instance, anyway I am in the UK so sending it back and forth would cost a bomb.

Regards rog8811

Apparently I'm an idiot for thinking titanium might make for good heatsinking material.
I'd better go with copper.

You'd better go with aluminum like everyone else.Copper is pretty nasty to machine too, aluminum , on the other hand , is pretty smooth.And the difference in heatsinking abilities is negligeable.
The aixiz nut thread can be done on the lathe if you don't have the right tap.I just finished making a pocket-mini a little different than jayrob did.It resembles your design a little because I made a thread for the aixiz module instead of using a set screw and I completely removed the LED assembly and accomodated the flexdrive inside my assembly.
Btw, I don't know if the 3mm would be enough to press fit and the 18mm diameter would have to be machined very precisely.You're better off with a thread there.

Titanium is almost impossible to machine without diamond cutters

phoenix77 said:

Titanium is almost impossible to machine without diamond cutters

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I know one of the hardest metals is chromium, harder than titanium.But anyway, metals are almost always best used in alloys.You can probably get harder stuff with some quenched alloys or tungsten carbide.But on 700+ MPa on the Brinell scale, titanium probably wouldn't be too easy to machine. :/ Do you have any experience with this?

Anyway, no point in making a heatsink out of it.

I have cut titanium before. It's a bitch to machine, but it can be done with carbide, as long as you keep a steady fllow of coolant, and never let the cutter idle in one place for more than 1 second. If it sits in one spot and just rubs, it heats the cutter up and shatters it.

Let me just make one thing clear: I won't be using titanium because it is no good for a heatsink. I tried to sell some titanium in the BST thread for anyone that wanted to machine it and use it as a heatsink, and I was attacked for having the idea that it could be used for heatsinking.

I think I'll make it out of copper and get it chromed.

Peace, Steve

Sorry, can i permit to give you a pair of suggestions ?

First, if you want something better than aluminium, use anticorodal (looks like aluminium, is more hard, conduct heat a bit better, and oxidize less - usually used in sailing carriers building and other similar applications)

Second, if you use an aixiz lens holder, why you don't use also the aixiz head ? ..... just do a hole of 12mm diameter and 9mm depth, with a lip at the end that is same depth, diameter and screw thread size of the aixiz head screw, then screw it inside, maybe using also a bit of thermoconductive glue, and this way you can first press easily the diode in the aixiz head, then screw / glue it in the dissipator ..... look the draw (and sorry for the bad quality, i've done it handy on-the-fly, cause i'm running at home, i'm in late) ..... just as idea

I'm trying to do something similar, but having no machines at home, i'm stopped, but if you have machines and can do the work, maybe the idea can be helpful for you

Lordoflasers, try PMing MISTERWILLING he has machined a few pieces for members of the forum.