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Old 07-15-2012, 08:10 AM #33
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Wink Re: Concept: 4W corrected 445nm handheld

Quote:
Originally Posted by ARGLaser View Post
Copper isn't that much better than aluminium, it's not a huge difference; the modules are copper though. I also despise the brown look of copper, and the front part of the heat-sink will be seen. I wont be pushing the diodes either, I changed the plan up some more. I'm probably going to run each diode @ 1.9A so there wont be as much heat.

.

Thanks!
Aluminum works but for stability sake Copper is 62.3% better than Aluminum at removing heat. k - W/(m.K) Aluminum 250W/(m.K) Copper 401W/(m.K)
Even better than Copper is Silver at 429W/(m.K)

I was just thinking from a thermal standpoint, you will be transferring quite a bit of waste heat from those diodes and the divers as well. best to go with something to remove the heat as fast as possible. You have a really nice build there.
@ ~5v 1.9A per diode which is nearly 10W per diode, how much of that input gets turned into waste heat/loss? You're inputting nearly 20W between those diodes. That host will need some decent cooling if you want any kind of life out of it.


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Old 07-15-2012, 08:29 AM #34
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Default Re: Build: 4W 445nm handheld

Hasn't the Cu / Al thing been flogged to death enough in other threads. ????
I'm more interested on his build, once it's complete we'll see how good Al performs.
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Old 07-15-2012, 09:17 AM #35
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Default Re: Build: 4W 445nm handheld

Quote:
Originally Posted by benmwv View Post
On a finned heatsink with a fan, sure the difference between aluminum and copper isnt that pronounced, but in a closed host copper is far superior. It has a much larger thermal capacity which means much longer duty cycles. Aluminum is just too light.
No it doesn't.

Sure, copper has 3.3x the mass (per unit of volume) that Aluminum does. But aluminum has around 2.3x the thermal capacity per unit of mass that copper does. So the actual specific heat capacity of copper is only very minimally higher than aluminum's on a volume basis (which is the basis you'd compare if building a specifically sized heatsink from one of the two metals).

In a build like this, it is all about specific heat capacity of the metal. The benefits of copper for the heatsink would be relatively small. The benefits of copper for the modules as heat transfer conduits TO the heatsink, would be huge (and it sounds like you've already come to that conclusion - so you're set).
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Old 07-28-2012, 11:22 PM #36
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Default Re: Build: 4W 445nm handheld

Wouldn't it be... If you are constrained by volume, copper will offer more heat capacity, while if constrained by mass, aluminum will offer more heat capacity.

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Old 07-29-2012, 10:52 AM #37
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Default Re: Build: 4W 445nm handheld

Quote:
Originally Posted by Mrcrouse View Post
Wouldn't it be... If you are constrained by volume, copper will offer more heat capacity, while if constrained by mass, aluminum will offer more heat capacity.
Exactly, in a build the host generally limits the size of the heatsink. So, unless you go for an elaborate larger custom HS for the Al, both an Al and a Cu heatsink for the same host will have the same volume. As RHD said Al has a higher specific heat capacity than Cu, but due to the fact that Cu has a higher density than Al, you would need to build a larger Al heatsink to account for it. Cu would thus have a smaller temp increase per joule of heat for the same volume HS, than Al.

Quote:
Originally Posted by Multimode View Post
Hasn't the Cu / Al thing been flogged to death enough in other threads. ????
I'm more interested on his build, once it's complete we'll see how good Al performs.
I agree!
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Old 07-29-2012, 11:30 PM #38
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Default Re: Build: 4W 445nm handheld

wow cant wait to see this thing in completed. Should be really awesome if it works out !
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Old 08-01-2012, 05:21 AM #39
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Default Re: Build: 4W 445nm handheld

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Originally Posted by kaunak View Post
wow cant wait to see this thing in completed. Should be really awesome if it works out !
I'll make it work, have already invested to much to not have it work

Host should be here any day now.
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Old 08-02-2012, 06:03 PM #40
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Default Re: Build: 4W 445nm handheld

The host arrived from Ehgemus today! It's a piece of art!

[Redacted]

Now the building can commence

Last edited by ARG; 08-03-2012 at 02:45 AM. Reason: removed bad photos
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Old 08-03-2012, 02:41 AM #41
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Default Re: Build: 4W 445nm handheld

My apologies for the above photos, it had just came in the mail and I was exited. I had somewhere to be so I couldn't spend a lot of time to take quality photo's or resize them so that I could embed them.

Here's some better ones!

The head of the laser


Drop in Heatsink
Front
A piece will be added onto the tray so that the optics don't move when the aluminium warps in the heat.

Back

The driver pocket with two wires for the two drivers


Battery tube for 2x 32600


Tailcap


Front side all together


I am in awe of how good this all looks! The pictures don't do it justice. Ehgemus polished it up real well, it's a mirror finish




Now... On to the build

I wrapped the lens threads with some teflon tape, almost two full wraps so that the fit was really tight. I focused them to infinity and I put some silicon on the top to hold it in place; even though it was already really tight with the teflon tape. The silicon is easy to remove if I need to change the diode. It's just an extra measure to make sure the lens don't wiggle or move at all.


I put them in the aixiz heatsinks temporarily to hold them while they cure. Now to wait 24h for it to dry.

Last edited by ARG; 08-03-2012 at 06:15 AM. Reason: Spelling
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Old 08-03-2012, 04:47 AM #42
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Default Re: Build: 4W 445nm handheld



How did i miss this thread.
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Old 08-03-2012, 04:50 AM #43
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Default Re: Build: 4W 445nm handheld

Well, the 445nm section is a hot topic Other threads keep bumping this one down

Can't wait to get those x-drives! This is what they are for Hopefully they will arrive next week.

Last edited by ARG; 08-03-2012 at 06:18 AM. Reason: Glaring spelling mistake
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Old 08-03-2012, 04:55 AM #44
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Default Re: Build: 4W 445nm handheld

Thats awesome.


Looking forward to watching this build.
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Old 08-03-2012, 06:03 AM #45
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Default Re: Build: 4W 445nm handheld

Thanks Lazeerer!

I borrowed a Power Supply so I could get some reading before I put the diodes in. The silicon has cured for the most part, so it's safe to fire them up.

Readings taken after 10 seconds on the sensor, to get an average reading. Rounded to the nearest multiple of 5. Small testing heatsink used, numbers will be higher once they are in the host's heatsink

Diode #1:
2070mW at 1.6A
2440mW at 2A
Diode #2:
2155mW at 1.6A
2590mW at 2A

Combined is 5W Leaves room for 20% optics loss on each diode! The loss should only be 10% on the better diode so 2331mW from that, and I expect 25% loss on the worse diode so 1830mW. Total 4161mW estimated. My optics loss estimates are fairly high, so it will likely be more than that!

This may even hit a 4.5W peak once this is all built!

Last edited by ARG; 08-03-2012 at 06:13 AM.
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Old 08-03-2012, 06:48 AM #46
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Default Re: Build: 4W 445nm handheld

Looks like you got some efficient diodes there.
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671nm 800mW PowerModulem, 9mW Black Pen
685nm 44mW MXDL 2x AAA Pen, 41mW, 130mW Stainless Shadow
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LPM's 2W/5W Ophir
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Old 08-03-2012, 06:17 PM #47
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Default Re: Build: 4W 445nm handheld

Got the X-drives from lazeerer in the post today




I've got to install the modules before the drivers and I'm waiting on some quality thermal grease to put around the modules for the better heat transfer. I could use a dab of thermal adhesive, but it would be a pain to remove the modules if need be, and I need to be able to rotate the modules to get both of the lines to be perfectly perpendicular to the optics tray.



The silicon has set completely and the lens barrels don't move at all It's easy to peel off to if I ever need to realign.
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Old 08-03-2012, 07:47 PM #48
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Default Re: Build: 4W 445nm handheld

Nice. Yeah your better off not using Thermal Adhesive. Like you said if you have to remove them or hell even make adjustments which iam sure your going to have to make quite a few to get it just right you would not want to have to chip away thermal adhesive.

How come you decided to go with Grease rather then paste.?

Is it better performing in your Opinion.?
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405nm 1013mW In Cree Z5 , 850mW LaserGLow Electra Mod , 583mW C3 BDR
445nm 3.6W Monster Freak TEC 9mm, 3.1W Fat Boy Build , 2.9W Big Stainless , 2.7W Big Black, 2W Arctic G2 , 1.8W C13
473nm 178mW CNI-PGL-III-C , 56mW CNI-PGL-III-C
488nm 52mW OPSL SAPPHIRE 488-50, 59mW SS Melles Griot BCD-50&BCD-25 35mW
515nm 83mW Direct Green Diode Fully Custom Host
532nm 617mW RPL Style , 213mW CNI-PGL-III-A , 120mW DIY SS C3
589nm 130mW CNI-PGL-III-A
594nm 13mW CNI-PGL-III-C
632nm 4mW HeNe
635nm 1130mW Fenix TK35 ML501P73 , 918mW Small Sun ZY ML520G71
650nm 1056mW Polished CNI-PGL-C Mod, 5W Custom Build Red Devil
658nm 430mW LOC 826 Brinyte A20 , LCC 390mW C3 3 mode
660nm 500mW SS LQ ignis
671nm 800mW PowerModulem, 9mW Black Pen
685nm 44mW MXDL 2x AAA Pen, 41mW, 130mW Stainless Shadow
780nm 127mW Pen
808nm 758mW Fire Dragon From DJNY
LPM's 2W/5W Ophir
SPECTROMETER - 390nm to 980nm



All My Reviews, Tips & Mods Are Here Now: >Reviews<


Check Out My YouTube Video's Here:
http://www.youtube.com/user/Lazereer
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