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Old 09-16-2009, 03:35 PM #33
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Default Re: New Experimental Heat Sink

Copper is always in demand. If you could do one for under $20 I think you would have a winner. Do a feeler in the BST section.

Send me one when you get it made. I'll test it for you. If I like it I'll buy, if not I'll send it back.


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Old 09-16-2009, 03:41 PM #34
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Default Re: New Experimental Heat Sink

Great suggestion on the BST feeler, will do.
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Old 09-16-2009, 04:31 PM #35
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Default Re: New Experimental Heat Sink

I dont see a need to do these in copper really... the limiting factor is still heat transfer to air, and the better conductivity of the copper will contribute very little to the performance compared to the increase in cost. Making it slightly longer than the aixiz would give more performance for a price increase.
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Old 09-16-2009, 05:27 PM #36
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Default Re: New Experimental Heat Sink

Nice work!

How much can you sell them for in aluminum. Benm is correct that Copper will not help enough vs cost.


Info:
Adding a press fitting on the HS directly to diode and tapping your own lense socket would help more too. By doing that you remove one junction and the thermal contuctive resistance (TCR) that comes with it. Every surface to surface junction adds resistance. When it comes to a set screw type HS you will almost always have a gap too. This gap creates a bunch of resistance as well. The 2 biggest reducers of TCR are surface contact and presure. The set screws can give you presure but not all around surface contact. Thermal past will add another junction but atleast it conducts better than air.

I think what you have is plenty for any diode I have played with. The info above is just that information.

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Old 09-16-2009, 05:41 PM #37
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Default Re: New Experimental Heat Sink

@ Sight, thanks for the information and it was well taken. I agree with you on the air gap between the AXI Mod and the HS, but I believe it is very minimal and yes paste will help. As for a press in that will be down the road once I get my lathe. I also agree on Alunimum vs. Copper on just the cost, so far it seems it will cost me 4x the amount to buy the block of copper compared to alunimum, however if there is a demand, and they except the price, I will make them.
Thanks again.

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Old 09-17-2009, 10:44 AM #38
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Default Re: New Experimental Heat Sink

Very nice looking heatsinks looks like they can do the job. Yea the cost of copper kinda out weighs the benifits here as a fan can easly be used to draw the heat away from these and make them more eff. since they will be in an enclosure with other stuff anyway. can't wait to try em out I'm getting close to having most of the parts for a nice RGB scanner and these might work realy well in there.

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Old 09-17-2009, 11:46 AM #39
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Default Re: New Experimental Heat Sink

Hey Flame, Thanks for the input and yes I did check out the cost for copper and it's a no go for now, way too expensive, plus it's a lot heavier the aluminum. I took the advice from Sightfx (great suggestion by the way Sight)and polished the inside of the HS last night and it is much easier to slip in and looks better. I will be talking to my metal guy today to see what the cost to anodize them is, however my only concern is by anodizing the HS, will it hold the heat instead of transferring it. So if anyone knows if anodizing the HS will be a problem, please let me know. If the cost is not too bad I will have him do 1 and then test it. As it stands now I tested it again last night with a brand new 9v battery for 30 minutes and still get the same results as before. The sink was a little warm but you could hold it in your hand comfortably. I am designing a hand held pistol grip with an adjustable focus slide so you can focus the AXI or the legendary Jayrob 405 G1 lens with your thumb while pointing the laser at your target, should be interesting. I will send you the HS once I get them polished on the inside and drilled and tapped for the set screw and mounting studs.
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Old 09-17-2009, 11:53 AM #40
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Default Re: New Experimental Heat Sink

Howdy Tym have you thought of drilling the hole for the Aixiz module first into the blanks and then water jetting the rest of it ?
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Old 09-17-2009, 12:12 PM #41
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Default Re: New Experimental Heat Sink

Yeah I did, however water jetting it then drilling was easier, plus it may not be exactly centered. Plus by letting the Flow cutter do all the work it eliminates one extra step. I did drill a 12mm hole in a piece of stock and it took too much time to get it just right by my standards (Iím lazy).
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Old 09-17-2009, 01:33 PM #42
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Default Re: New Experimental Heat Sink

Making the diode and lens socket and thread would probably add a lot of work and required precision - i'd say the 'fits around aixiz' approach is fine.

If you are planning on selling them i'd be interested. A good 'option' would be to sell them in various lengths. Having one even longer than the aixiz would be good for continous operation with the most powerful diodes.
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Old 09-17-2009, 01:59 PM #43
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Default Re: New Experimental Heat Sink

Again another great suggestion Benm, I am changing the length to 1 1/4" so the whole AXI Mod will be covered. If demand is high on longer and bigger HS's I will entertain the idea of custom length HS's. Also once I find a latte I will try making one that is press in, however that another story.
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Old 09-21-2009, 12:56 PM #44
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Default Re: New Experimental Heat Sink

I ordered a new piece of aluminum stock today that will be 1 1/4" thick so the sink will enclose the whole AXI Mod. I also changed the location of the flat set screw/mounting area to be centered between the long fins so the fins will not interfere with mounting and it makes it a little easier to screw the mounting studs and tighten the set screw. If you look at the picture you will see what I am taking about on the bottom where the set screw is. I hope to be sending out a couple of review sinks this week but they will be the 1” thick ones. It will take a couple of days to get the 1 1/4” stock, get them made and cleaned up, drilled and taped. Pictures will follow on the hopefully FINAL design maybe.
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Old 09-21-2009, 02:30 PM #45
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Default Re: New Experimental Heat Sink

Having one of the fins removed might make it easier to install indeed.

One other thing: perhaps it would be less work if you left all the fins as large as the stock was. I'd be more of a square than a round shape, but would actually be more effective at its job.
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Old 10-02-2009, 12:57 PM #46
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Default Re: New Experimental Heat Sink

@ Flaminpyro and Daguin your heatsinks went out yesterday. Flaminpyro your's should be to you in 3 days and Daguin yours in 5. Let me know what you think, thanks.
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Old 10-08-2009, 02:19 PM #47
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Default Re: New Experimental Heat Sink

Finally I have what I think is the last revision of the heat sink. As I had posted I was only making these for my project, but since I got several PM’s asking if I would sell these I figured I would make a couple more to see if they sell. Thanks to fellow forum members with their very helpful suggestions, I have made the modification they recommended. The sink is 1ľ” long so it completely incases the Aixiz Module, the hole has been reduced so the module is a very tight fit but can still be installed with your fingers. I have drilled and tapped a 6-32 hole and installed a set screw in the center of the sink with 2 pilot holes that can be drilled out and tapped for mounting studs of your choosing. Again I tested this for 30 minutes with a 405 Blu-Ray diode using the Jayrob 405-G-1 lens and found it to be just warm to the touch. I am selling these for $22 plus $2.00 for shipping if anyone is interested, just PM me. I have 7 completed now and will make more when I run out. Thanks again for all the help, my project works great with the HS’s.






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Old 10-08-2009, 02:22 PM #48
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Default Re: New Experimental Heat Sink

looks good, congrats on finishing this, finally! :-)
its so much nicer to have the components built by yourself, not?

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