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Old 01-20-2014, 11:35 PM #1
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Default Maser - Active Cooled MagLite 2D laser 445nm

--- confirmed 2.674 watt laser

Since this forum has given so much to me I thought I'd return the favor.
I've built this laser with the need to kill aiptasias in my fish tank that has grown in large numbers. I needed something that has the power to penetrate salt water and have a relatively high duty cycle. The previous laser I had, a 2.4w 445nm laser got too hot too quickly. With a 60 - 120 second on time and equal time cooling, I just wasn't accomplishing my task. Because I've got to penetrate 3/4" acrylic then in thru salt water, I needed to leave the laser on the target longer or get something more then 3W. I quickly realized that even with 3W and continuous use tho, my effective range is 6" from the acrylic. My next build will be a dual diode laser. But anyway for now I can easily accomplish long duty cycles.

This build is a light weight Maglite with active cooling. I don't have an LPM so I don't know the wattage.

parts:
1 2D cell Maglite
1 9mm 445nm diode with Xdrive @ 2.4amps , G2 lenses
1 Aluminum Heatsink Cooling Cooler Heat Spreader for 3W LED Light Bulb
heatsink found on ebay for $5 from china.
Its got a diameter of 53nm and height of 23mm, hole is 11mm
2 36650 cells
1 foam
1 25mm x 25mm Sunno Fan
1 standoff
and a bunch of misc hardware


The setup keeps the laser relatively cool even when left on continuously. I'd say about 94 degrees at the warmest areas. The driver is sandwiched between 2 pieces of aluminum and integrated into the heatsink on both sides. Only 1 standoff is required hold the fan in place. Foam is glued to fan as a shroud to force air thru the fan and move air out of maglite. 4 Holes were drilled near the power buttons for air intake.

The heatsink is held in place by the maglite lense cover holder. the cap at the end of this maglite had to machined down so the spring is recessed in to allow for more room for the 36650.

The heatsink won't fit as ordered. You must have a lathe and cut the outer diameter down, AND bore out the the inner hole to 12mm. A mill will also be required to drill 3 holes for the standoff for the fans, and 2 set screws to hold down the diode AND the heatsinks for the drivers.

The entire build was relatively cheap and effective.
$5 for the heatsink
$5 for the fan
$150 for the diode
$20 for the maglite
$44 for the batteries

The weight of this is almost same as a fully functioning 2D maglite.
Attached Thumbnails
Maser - Active Cooled MagLite 2D laser 445nm-resize-maser08.jpg   Maser - Active Cooled MagLite 2D laser 445nm-resize-maser01.jpg   Maser - Active Cooled MagLite 2D laser 445nm-resize-maser02.jpg   Maser - Active Cooled MagLite 2D laser 445nm-resize-maser03.jpg   Maser - Active Cooled MagLite 2D laser 445nm-resize-maser04.jpg  

Maser - Active Cooled MagLite 2D laser 445nm-resize-maser05.jpg   Maser - Active Cooled MagLite 2D laser 445nm-resize-maser06.jpg   Maser - Active Cooled MagLite 2D laser 445nm-resize-maser-data.png  



Last edited by andyman; 01-28-2014 at 05:24 AM.
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Old 01-20-2014, 11:58 PM #2
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

Wow, greath 5th post!

The fan does look VERY cool, in fact the whole laser is a stunner!
Great that it perfectly fit the top.

+1 from me
and I΄m sure some +rep from others gonna follow for this nice built



The price of the G2 lense is included here?

Quote:
Originally Posted by andyman View Post
1 9mm 445nm diode with Xdrive @ 2.4amps , G2 lenses

$150 for the diode
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Last edited by DJNY; 01-21-2014 at 12:13 AM.
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Old 01-21-2014, 02:33 AM #3
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

Aye, +rep from me! This has to be the simplest, most inexpensive way in achieving [efficient] active cooling in a host. Super awesome!
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Old 01-21-2014, 02:45 AM #4
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

Wow defiantly a great effective way to achieve active cooling. Very nice!!
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Old 01-21-2014, 02:58 AM #5
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

Nice. much better looking than my fan cooled build Where does the fan suck in air? if it's just the little hole near the button, you might want to add a bit more for more airflow
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Old 01-21-2014, 03:29 AM #6
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

It may not be obvious in the photos but there are 4 holes spaced 90 degrees apart. Trust me theres enough airflow.
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Old 01-21-2014, 10:46 AM #7
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

Excellent MagLite build andyman, with two 32650's and active cooling,
you ought to be "good to go" till you build that dual diode monster!

+1 Nice Job!
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Old 01-21-2014, 11:05 AM #8
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

Sweetness. I've got one coming up real soon keep an eye out.
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Old 01-21-2014, 07:12 PM #9
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

Very nice, I've been wanting to do an active cooling build too. You make it look easy. +rep
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Old 01-21-2014, 10:18 PM #10
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

Excellent job, I've been working on something similar.
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Old 01-28-2014, 04:42 AM #11
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

Here is the data to backup the build.
2.675W average
3600 seconds test time
85.5degree F start temp, 90.2 F at half way, 96.0 F at the end of the 1hr test.

I've updated the LPM output
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Old 01-28-2014, 05:23 AM #12
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

Impressive! Takes a while for the power to drop as well, still 2.8W after 5 minutes or so.

Great build mate.
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Old 01-28-2014, 12:03 PM #13
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

Awesome!
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Old 01-28-2014, 12:13 PM #14
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

My extended maglite is very similar in performance. It doesn't drop even at 5 min and I just took the huge heatsink approach

Very nice build. You got me thinking what mine could do with a fan. I was a good move giving the driver some extra help handling 2.4a

+1
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Old 01-28-2014, 03:08 PM #15
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

Has anyone else posted their builds with LPM posted on extended runs (1hr test or more?). I'd love to see performance numbers from others so I know how the power compares.
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Old 01-28-2014, 03:32 PM #16
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Default Re: Maser - Active Cooled MagLite 2D laser 445nm

I have yet to get mine tested at all I have more builds in mind. I am already working on my next build and it also has some sweet tricks going into it.
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