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Old 08-11-2010, 05:44 AM #1
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Default Big Maglight 1W 445nm

So im obviously new here but I have been reading quite a few threads on the 445nm 1W diode and so I think I have most of it figured out but still have a few questions.

This is the parts list I have so far

The laser diode

Micro FlexDrive Driver

Big Heat sink - most should fit in the big Maglight host

Focusing Lens - Not sure what lens

Module - depending on the type of heat sink

Batteries - Not sure but the original flashlight takes several Ds so anything should fit

Do I have everything?


And now I have a few questions if anyone could be so kind as to answer them.

1. With that driver can I trust the preset current that I specify upon ordering? I plan to run about 900mA which I would imagine with a large heat sink and short duty cycle should be safe.

2. If using a heat sink how does one mount a focusing lens and what lens should be used? Should I just order the diode pre-mounted in a module and then find a heat sink to fit the module?

3. Will running the standard D batteries work fine or should I got with some other rechargeable battery?

4. Also do people use IR filters? I know the all the wicked lasers run them but I havent seen anything about them in peoples posts.

Thanks everyone in advance! Im excited to get this thing rolling and ill make sure to post lots o pics.


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Old 08-11-2010, 11:14 AM #2
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Default Re: Big Maglight 1W 445nm

1. i have no reason to believe that the preset current would be any different than what you specify, however i'm not familiar with flexdrives.
2.you would normally use an aixiz module, you can screw the lens into that.
3.depends how many D batteries it takes
4.ir filters are only needed on dpss lasers
5. welcome to the forum
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Old 08-11-2010, 09:36 PM #3
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Default Re: Big Maglight 1W 445nm

Awesome! Thanks

Does it seem that I have everything in order? Although I tinker a lot I have never built a laser before.

The only other question I have at the moment is how people mount their heat sinks to the host. Epoxy should work but its seems it would dissipate heat much more effectively if it could be secured to the aluminum shell in a more heat conductive fashion.
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Old 08-11-2010, 10:45 PM #4
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Default Re: Big Maglight 1W 445nm

it dose seem you got it all. how good are you at soldering?
as far as a heat sink most people make them in a lathe to fit the host.
oh and you can find a diode for cheaper around here.
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Old 08-11-2010, 11:31 PM #5
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Default Re: Big Maglight 1W 445nm

There is something missing from your list: goggles. You really, really don't want to operate a 1W laser without the proper safety gear. These are quite dangerous, and without the necessary gear you will have an accident - it's just a matter of time.
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Old 08-11-2010, 11:33 PM #6
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Default Re: Big Maglight 1W 445nm

there are a couple ways you can go with the heatsink.

Radial design PC heatsink turned down.
A massive surface area this will disipate heat as fast as you can make it. Get the driver sinked and you are golden. The issue is they need to be in the open to work well and they usually harm aesthetics.

Large solid heatsink.
These are used in smaller designs a lot because if you went for increased surface area in a small form factor youd most likely wouldn't get enough before you would have taken away too much mass. Instead they aim for mass to soak up the heat and use a duty cycle to let that built up heat dissipate. They also arent affected much by being internal.

Either one you use, you can buy thermal epoxy online, though a tight fit plus some thermal compound is better since it can be worked on.

Last edited by oic0; 08-11-2010 at 11:35 PM.
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Old 08-12-2010, 12:31 AM #7
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Default Re: Big Maglight 1W 445nm

Where would I buy one here? I'm new and my internet at my house is down so I haven't had much time to explore. I'm on a blackberry at the moment so it takes awhile to get much accomplished haha.

I might also use a different host as I have found a nice heavy duty aluminum 3W led
flashlight. It has a built in charger and the battery pack looks like 3 cr123s shrink wrapped end to end. I'm thinking that I can leave the charger alone and just run the driver off the lead to the led and then ground to the case. Any thoughts on this?

Edit:

Ill get right on ordering a few sets of laser shades - good idea

I figured heat sinking would be key. If you can keep it cool is it fine to run it for long periods?

Last edited by Braddubya; 08-12-2010 at 01:26 AM.
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Old 08-12-2010, 12:42 AM #8
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Default Re: Big Maglight 1W 445nm

http://www.lands.rice-precision.com/...er_diodes.html
GB 445nm diodes For Sale $45
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Old 08-12-2010, 01:10 AM #9
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Default Re: Big Maglight 1W 445nm

Quote:
Originally Posted by Braddubya View Post
So im obviously new here but I have been reading quite a few threads on the 445nm 1W diode and so I think I have most of it figured out but still have a few questions.

This is the parts list I have so far

The laser diode

Micro FlexDrive Driver

Big Heat sink - most should fit in the big Maglight host

Focusing Lens - Not sure what lens

Module - depending on the type of heat sink

Batteries - Not sure but the original flashlight takes several Ds so anything should fit

Do I have everything?


And now I have a few questions if anyone could be so kind as to answer them.

1. With that driver can I trust the preset current that I specify upon ordering? I plan to run about 900mA which I would imagine with a large heat sink and short duty cycle should be safe.

2. If using a heat sink how does one mount a focusing lens and what lens should be used? Should I just order the diode pre-mounted in a module and then find a heat sink to fit the module?

3. Will running the standard D batteries work fine or should I got with some other rechargeable battery?

4. Also do people use IR filters? I know the all the wicked lasers run them but I havent seen anything about them in peoples posts.

Thanks everyone in advance! Im excited to get this thing rolling and ill make sure to post lots o pics.
Just reading some of the 445nm 1W diode threads are not enough to have most of it figured out. There is much more to building a laser than just what is contained in those threads.

Two really good threads you should read about building a laser are located in my sig, check those out.

Usually the driver will come pre-set to to current you specified but it is possible for something to happen to it in the mail, and people are human, mistakes can be made. It has happened before. Personally, I always check the set current if I order pre-set because I don't want fry my diode.

Quote:
Originally Posted by Braddubya View Post
Awesome! Thanks

Does it seem that I have everything in order? Although I tinker a lot I have never built a laser before.

The only other question I have at the moment is how people mount their heat sinks to the host. Epoxy should work but its seems it would dissipate heat much more effectively if it could be secured to the aluminum shell in a more heat conductive fashion.
I depends on the host on how the heatsink is mounted. I have three different DIY lasers and all three are mounted differently. My Jayrob SS CR2 build has a pill that screws in behind the host to hold it in. My Ehgemus custom, the heatsink screws directly into the body. And My MXDL's heatsink is pressed between the body and the lens cap.

Quote:
Originally Posted by AdamCaudill View Post
There is something missing from your list: goggles. You really, really don't want to operate a 1W laser without the proper safety gear. These are quite dangerous, and without the necessary gear you will have an accident - it's just a matter of time.
Very, Very, VERY important with any laser use, never mine a 1W monster! You only get one set of eye man, protect them!

Quote:
Originally Posted by Braddubya View Post
Where would I buy one here? I'm new and my internet at my house is down so I haven't had much time to explore. I'm on a blackberry at the moment so it takes awhile to get much accomplished haha.

I might also use a different host as I have found a nice heavy duty aluminum 3W led
flashlight. It has a built in charger and the battery pack looks like 3 cr123s shrink wrapped end to end. I'm thinking that I can leave the charger alone and just run the driver off the lead to the led and then ground to the case. Any thoughts on this?
You can buy DIY kits or just heatsinks from several people on the forum. Check the pro shop for their FS threads.

A flexdrive has an input voltage of 2.0 -5.5V so using 3 CR123s would be too much unless you used some rectifier diodes to drop the voltage. Or you could use a different driver, like a linear driver (LM317, or the groove 2). So you have to find the right combination of size of host, batteries (Li ion, primary, NiMH etc...), and driver. Usually pick a host, and work around that.

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Old 08-12-2010, 03:46 AM #10
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Default Re: Big Maglight 1W 445nm

Quote:
Originally Posted by Kevlar View Post
Two really good threads you should read about building a laser are located in my sig, check those out.
I read one already and am currently reading the other. Thanks!

Quote:
Originally Posted by Kevlar View Post
A flexdrive has an input voltage of 2.0 -5.5V so using 3 CR123s would be too much unless you used some rectifier diodes to drop the voltage. Or you could use a different driver, like a linear driver (LM317, or the groove 2). So you have to find the right combination of size of host, batteries (Li ion, primary, NiMH etc...), and driver. Usually pick a host, and work around that.
The battery pack says 3.6V right on it....maybe its not cr123s

I really just need to know the voltage at the LED anyway so ill go grab the multi.
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Old 08-12-2010, 05:50 AM #11
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Default Re: Big Maglight 1W 445nm

I think im going to go back to the Maglite host to eliminate the extra variables created by the built in charger. Plus I will have more room for a good heat sink.

The maglite runs on 3 Ds so thats 4.5V. Am I correct in believing this will require a combination driver to run the diode? I read the voltage drop is between 4-4.5V so because its so close neither a boost or linear will cover both possibilities....right?

If I am correct does anyone suggest a certain combination driver? I did a search and didnt come up with anything.

edit:

Now im all confused. is the flexdrive a combination? Im thinking it is.

Last edited by Braddubya; 08-12-2010 at 06:11 AM.
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Old 08-12-2010, 02:06 PM #12
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Default Re: Big Maglight 1W 445nm

Quote:
Originally Posted by Braddubya View Post
So im obviously new here but I have been reading quite a few threads on the 445nm 1W diode and so I think I have most of it figured out but still have a few questions.
Focusing Lens - Not sure what lens
You are going to need a negative focal length lens also. Before you start putting this together think about the optical system it's just as important as everything else.
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Old 08-12-2010, 02:22 PM #13
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Default Re: Big Maglight 1W 445nm

Quote:
Originally Posted by Braddubya View Post
I think im going to go back to the Maglite host to eliminate the extra variables created by the built in charger. Plus I will have more room for a good heat sink.

The maglite runs on 3 Ds so thats 4.5V. Am I correct in believing this will require a combination driver to run the diode? I read the voltage drop is between 4-4.5V so because its so close neither a boost or linear will cover both possibilities....right?

If I am correct does anyone suggest a certain combination driver? I did a search and didnt come up with anything.

edit:

Now im all confused. is the flexdrive a combination? Im thinking it is.
No, you are fine to run a flexdrive at 900ma at 4.5v input. You will need a 405nm glass lens for the laser, because the acrylic lens will degrade over time. Any other questions feel free to PM me or ask here!

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Old 08-12-2010, 05:15 PM #14
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Default Re: Big Maglight 1W 445nm

Alright thanks everyone! I placed some orders last night.

Here is what I have coming in the mail:
Flexdrive preset at 1A
1W 445nm diode
12mm module
12mm Aluminum finned heat sink
30x30mm cpu fan (we will see if I can fit it haha)
405nm coated glass lens

As far as batteries I think I will just run regular D cells unless you guys recommend something else. It should have a long bat life for a 1W.

Can wait to get my parts!
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Old 08-12-2010, 06:15 PM #15
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Default Re: Big Maglight 1W 445nm

I would recommend assembling a dummy load. I know your driver is coming preset but there is a good chance that the pot could get bumped at some point. Also read the driver's directions carefully before attempting anything and its always a good precaution to drain any residual current from the output capacitors on the flex drive before ever connecting the diode. Make sure all solder joints are strong and clean. If the driver and the diode are disconnected, even for a fraction of a second, then reconnected the capacitors will charge and rapidly discharge into the diode and kill it. This may also damage the driver as it not meant to be powered without a load. Good luck on your build and do some searching on dummy loads its a good thing to have and it shouldn't cost you more than a couple dollars.
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Old 08-12-2010, 09:03 PM #16
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Default Re: Big Maglight 1W 445nm

Ok ill make sure to drain the caps.

If I mount the driver straight to the diode inside the module will that heat sink the driver? Or do people do it some other way?
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