Concept: 28/56 watt multi diode combined laser "Wizards Staff"

I've been thinking of doing a combined laser build ever since I seen jander6442's Belphegor build.

I figured at first that combining 2 NUBM44s with a cube would be fun.

Then I started thinking about how much power it would need... Specifically batteries. I'd need at least 4 32650s to pull it off, that means a 4D maglite.

Then I watched "Monty Python and the Holy Grail" while surfing LPF and there is "Tim?" blasting stuff and I thought... Hmmm, a laser staff... Now that would hold all the lithium batteries I could want.

So why not 4/8 diodes, 2/4 PBS cubes and a knife edge assembly to combine them together?

So far I can't think of any reason it wouldn't work.

So, a 28 or even 56 watt "handheld" laser.

Thoughts, feelings, ideas?

AaronT said:

I've been thinking of doing a combined laser build ever since I seen jander6442's Belphegor build.

I figured at first that combining 2 NUBM44s with a cube would be fun.

Then I started thinking about how much power it would need... Specifically batteries. I'd need at least 4 32650s to pull it off, that means a 4D maglite.

Then I watched "Monty Python and the Holy Grail" while surfing LPF and there is "Tim?" blasting stuff and I thought... Hmmm, a laser staff... Now that would hold all the lithium batteries I could want.

So why not 4/8 diodes, 2/4 PBS cubes and a knife edge assembly to combine them together?

So far I can't think of any reason it wouldn't work.

So, a 28 or even 56 watt "handheld" laser.

Thoughts, feelings, ideas?

Click to expand...

The head of your staff is going to be huge. You need to think of how much space all those optics take up plus the heatsink required to dump all that heat. Also, better to knife edge then PBS with one cube rather than use two cubes and knife edge those. It'll make for one nasty fat beam whatever way you do it too.

So certainly possible, maybe just not all that practical.

Double post.

diachi said:

The head of your staff is going to be huge. You need to think of how much space all those optics take up plus the heatsink required to dump all that heat. Also, better to knife edge then PBS with one cube rather than use two cubes and knife edge those. It'll make for one nasty fat beam whatever way you do it too.

So certainly possible, maybe just not all that practical.

Click to expand...

Practical? What practical reason does anyone have for a handheld class IV laser?

Judging by the size of the head of the maglite in jander6442's Belphegor build I was thinking of making the PBS cube assemblies as modules placed around a central knife edge assembly.

This would allow me to build a single "module" first and likely I would use a 4D maglite as a temporary host/test bed. It would also allow me to figure out runtime, durability, power requirements, changes needed etc, as well as make for a good "4D Monster maglite" build thread on the forum.

Once I have two modules they could be combined with the knife edge assembly.

At that point I'd have a 28 Watt "staff"

For 56 watts I'd just need 2 more modules.

My motivation is more to learn about combining lasers and building laser assemblies. I like an engineering challenge, the end result is just a bonus.

I always thought of making a staff of some sort but I wanted mine to actually be about 2-4 ft long and hold 4 uncombined NUBM44s and then a 1W 520nm w/ beam expander in the center. It's hard to explain it so I might do a crappy drawing/concept of it in MS paint :crackup:

I'm not very good with my photoshop or cinema 4D yet so MS paint will have to do.

AaronT said:

Practical? What practical reason does anyone have for a handheld class IV laser?

I wasn't meaning the power output is impractical, just the size of the thing that's going to be impractical. Don't know if it's going to be all that "handheld". Especially if you have enough mass/big enough heatsink to handle all that power for any length of time. 4 diodes are going to be dumping ~50W of heat, perhaps more depending on what you run them at - just from the diodes - the drivers will add some. You also won't see quite 28W out unless you're running your diodes a little over 7W each - got to account for some optical losses. Should be close enough to 28W though.

Judging by the size of the head of the maglite in jander6442's Belphegor build I was thinking of making the PBS cube assemblies as modules placed around a central knife edge assembly.

As I said, you can use multiple PBS cubes and then knife edge them, but that's not the easiest/cheapest way to do it. PBS cubes for one are typically far more expensive than first surface mirrors - not to mention you'll probably need more waveplates - one for each PBS cube that you use. If you knife edge then PBS you only need one cube and one waveplate. Actually - you could omit the waveplate if you're going with one PBS. You could just knife edge 4 diodes and be done with it...

This would allow me to build a single "module" first and likely I would use a 4D maglite as a temporary host/test bed. It would also allow me to figure out runtime, durability, power requirements, changes needed etc, as well as make for a good "4D Monster maglite" build thread on the forum.

Once I have two modules they could be combined with the knife edge assembly.

Again, see above regarding PBS/KE.

At that point I'd have a 28 Watt "staff"

For 56 watts I'd just need 2 more modules.

And >100W of heat to dump. Going to be needing some air cooling in there - or a pretty large chunk of metal if you want a reasonable duty cycle. Maybe you don't mind a real short duty cycle though . Shouldn't need much run time at 56W to destroy things...

My motivation is more to learn about combining lasers and building laser assemblies. I like an engineering challenge, the end result is just a bonus.

I take it you have access to a drill press/drill bits/tapping bits? You'll be needing those.

Click to expand...

Not trying to put you down - just making sure you know what you're getting into. I'm all for experimenting and learning new things.

diachi said:

Not trying to put you down - just making sure you know what you're getting into. I'm all for experimenting and learning new things.

Click to expand...

I'm not really looking for it to be all that portable, nor could I think of why I would run it for more than a few seconds. I understand that it may not be a true "28/56 Watt".

I have priced components and understand there are less expensive ways to do this project, using PBS cubed modules allows me to start the project with less than 1/4 the required funds and have a fully functional 12-14 Watt handheld that I can experiment with.

Depending on how well the module/4D maglite combo build goes, I may try to get funds for the project by offering a couple for sale on the forum. This is not a project I would complete in just a month or two.

Like I said I couldn't think of why I would need a duty cycle more than a few seconds. At 28 Watts this thing would instantly ignite just about any indoor surface instantly. Using this outside would have the same issue. Discharging this device would require similar considerations that I use for firearms, like who may be observing, being sure of the target and backstop.

Yes I have the tools needed for the project including a drill press taps etc. I also plan to get a bench top lathe at some point though it probably isn't strictly needed for this project.