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Old 06-21-2012, 11:47 PM #17
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Default Re: optical head with plexiglass frame

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Originally Posted by Ramsey_innovations View Post
Ah so the modules won't be tightly seated against the heat sink then. This method will work but has it's obvious downfalls.....anyway it looks pretty cool so kudos to you
Many thanks.
You are referring to the thermal continuity... over the modules there is a custom made thermal compound made of a thermal paste mixed and saturated with chemical aluminum powder so there is an optimal thermal continuity between modules and the heatsink. This thermal contact is even better than a simply mechanical contact because it extends over all the surfaces and not only the mechanical seating surface.



Last edited by laserluke; 06-21-2012 at 11:48 PM.
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Old 06-21-2012, 11:53 PM #18
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Default Re: optical head with plexiglass frame

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Ill bet the plex will give off a nice glow when its running.
You are right, the plexiglass is glowing with the scattered light.
I will post other photos when completed the final electrical connections and the beams alignment

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Old 06-22-2012, 01:16 AM #19
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Default Re: optical head with plexiglass frame

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You are right, the plexiglass is glowing with the scattered light.
I will post other photos when completed the final electrical connections and the beams alignment
Can't wait
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Old 06-22-2012, 04:07 AM #20
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Default Re: optical head with plexiglass frame

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Originally Posted by laserluke View Post
Many thanks.
You are referring to the thermal continuity... over the modules there is a custom made thermal compound made of a thermal paste mixed and saturated with chemical aluminum powder so there is an optimal thermal continuity between modules and the heatsink. This thermal contact is even better than a simply mechanical contact because it extends over all the surfaces and not only the mechanical seating surface.
Well that was one of the potential issues with that method....i guess if the gap is minimal, but then adjustment is limited....
One other potential issue is de-alignment due to thermal expansion (creep). Adjustment via set screws in that type of configuration is often seseptable to this because of slight variations in temperature between the module, set screws and heat sink. If relatively moderate output diodes or conservative input currents are used, along with short duty cycles you most likely won't have any issues. However even the slightest movement will result in far field misalignment.
Just something to be aware of, you probably already know....
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Old 06-23-2012, 05:22 PM #21
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Default Re: optical head with plexiglass frame

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Originally Posted by Ramsey_innovations View Post
Well that was one of the potential issues with that method....i guess if the gap is minimal, but then adjustment is limited....
One other potential issue is de-alignment due to thermal expansion (creep). Adjustment via set screws in that type of configuration is often seseptable to this because of slight variations in temperature between the module, set screws and heat sink. If relatively moderate output diodes or conservative input currents are used, along with short duty cycles you most likely won't have any issues. However even the slightest movement will result in far field misalignment.
Just something to be aware of, you probably already know....
Many thanks for your informations. I have observed the problems you are speaking about.
You are absolutely right, the thermal stress produces misalignment and the heat produced by the two diodes is very high (at 4.7Vf each and 1.8A, we have 17W, 4.5-5W of light and 12W of heat...).
The optical head has no problems because it's thermally isolated by the heatsink with nylon screws and spacers.
I think also that using conservative input currents or short duty cycles is wrong, because we are trying to maximize efficiency to maximize run time and we are pushing the diodes to their limits to get more power. If i need to limit the use i would prefer to use one diode only pushed to it's limits with no alignment problems...
A smart solution is probably the use two very short, polarization-maintaining fiber optics to couple the diodes with the optical head leaving the diodes free to move with heat and the user happy to use the hand-held for a long time with high power... but this solution could be costly and also increase the size...
What do you think? Do you agree? Any suggestion for the fiber we could use?
-Luke

edit: the diode-fiber coupling efficiency could be a problem...







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optical head with plexiglass frame-img1.jpg   optical head with plexiglass frame-img2.jpg   optical head with plexiglass frame-img3.jpg   optical head with plexiglass frame-img4.jpg  

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Old 06-23-2012, 05:28 PM #22
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Default Re: optical head with plexiglass frame

Ok that is the sickest thing I've seen

The fibers sounds like a good idea, or maybe just use the same material for the set screw heatsink & module.
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Old 06-23-2012, 05:56 PM #23
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Default Re: optical head with plexiglass frame

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Ok that is the sickest thing I've seen

The fibers sounds like a good idea, or maybe just use the same material for the set screw heatsink & module.
It's a very monster... it burns almost instantly a white sheet of paper at 40cm and you must use the goggles because the brightness is terrible
Obtaining a good alignment it's a nightmare... Ramsey is right...

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Old 06-23-2012, 06:16 PM #24
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Default Re: optical head with plexiglass frame

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It's a very monster... it burns almost instantly a white sheet of paper at 40cm and you must use the goggles because the brightness is terrible
Obtaining a good alignment it's a nightmare... Ramsey is right...
Yeah... Well once you got that alignment it looks amazing though...
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Old 06-23-2012, 08:14 PM #25
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Default Re: optical head with plexiglass frame

What a beauty, an electronic - mechanical - optical, delight.

I look forward to reading you posts and updates.
ATB
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Old 06-24-2012, 03:26 AM #26
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Default Re: optical head with plexiglass frame

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What a beauty, an electronic - mechanical - optical, delight.

I look forward to reading you posts and updates.
ATB
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Many thanks, i'm happy you like it
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Old 06-24-2012, 04:51 AM #27
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Default Re: optical head with plexiglass frame

As fas as fibre coupling goes, I have not personally done this for combining but in our applications it would likely reduce efficiency due to the added necessary optics for collimating. There is a gentleman local to me who is a leading expert on combining. His preferred method is to fibre couple and combine via volume bragg gradings. Of course this comes with a hefty price tag and can be complicated to design, not to mention the laser's wavelength must be very stable and without active temperature control that can be hard to achieve. The pay off though is very high efficiency and damage threshold.
In my opinion, for our purposes I would suggest taking at look at how most labs and professional projectors achieve beam combining. The laser is in a fixed position and well heat sunk and the optics are adjustable....not the other way around....
Because my company does have a patent pending on a combiner module it is in my best interest to not go any further into detail about configurations, optics etc.... I'm sure you can understand. Unfortunately production of the module has hit some bumps in the road and things in my life (ie. Kids and work) have forced me to put this on hold several times. The good news is I'm past the hold ups and I'm back to production....
Best of luck to you on your endeavours, your work looks very good, keep it up!
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Old 06-24-2012, 01:08 PM #28
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Default Re: optical head with plexiglass frame

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As fas as fibre coupling goes, I have not personally done this for combining but in our applications it would likely reduce efficiency due to the added necessary optics for collimating. There is a gentleman local to me who is a leading expert on combining. His preferred method is to fibre couple and combine via volume bragg gradings. Of course this comes with a hefty price tag and can be complicated to design, not to mention the laser's wavelength must be very stable and without active temperature control that can be hard to achieve. The pay off though is very high efficiency and damage threshold.
In my opinion, for our purposes I would suggest taking at look at how most labs and professional projectors achieve beam combining. The laser is in a fixed position and well heat sunk and the optics are adjustable....not the other way around....
Because my company does have a patent pending on a combiner module it is in my best interest to not go any further into detail about configurations, optics etc.... I'm sure you can understand. Unfortunately production of the module has hit some bumps in the road and things in my life (ie. Kids and work) have forced me to put this on hold several times. The good news is I'm past the hold ups and I'm back to production....
Best of luck to you on your endeavours, your work looks very good, keep it up!
Sincerely thanks.
This is for me an hobby because i work at the university on different arguments. This hobby is sometime costly in several ways (i have two kids and a very tolerant wife ) so it is nice to receive a compliment.
Best of luck to your life, it was nice to meet you
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Old 06-24-2012, 04:03 PM #29
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Default Re: optical head with plexiglass frame

Ah it seems we have a quite a bit in common then.... I have two boys and a very supportive and understanding wife as well. Yes compliments can go a long way, helps to motivate future work.
Now that we are official friends here, you can take a look at my private album. There you will find several pics of the prototypes I've made prior to designing the production model. Just a sneak peak though...
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Old 06-25-2012, 12:41 AM #30
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Default Re: optical head with plexiglass frame

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Ah it seems we have a quite a bit in common then.... I have two boys and a very supportive and understanding wife as well. Yes compliments can go a long way, helps to motivate future work.
Now that we are official friends here, you can take a look at my private album. There you will find several pics of the prototypes I've made prior to designing the production model. Just a sneak peak though...
Very nice collection with special care for the design
However i must say that the best design is shown in the photo named "best friends"

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Old 06-25-2012, 02:55 AM #31
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Default Re: optical head with plexiglass frame

Thank you very much for the compliments! They truly are best friends, James has grown so fast and now my youngest, Anthony is already the same age as James was in that pic.....wow time flies!!!
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80mw-130mw 405nm (12+ builds) PHR803T harvested from sleds
>200mw 405nm (3x) SF-AW210
>500mw 405nm (2x) 10XBDR-S06
>100mw 532nm (4x) O-like modules
>80mw 532nm (3x) "fleabay" modules
>200mw 532nm (1x) Trilights "150mw" TEC cooled, TTL Lab module
<5mw 632nm (1x) Lasiris Inc. Lab module
150mw->300mw 650nm (10+ builds) LOC harvested diodes
100mw 660nm (10x) 9mm can, unknown Manufacturer
>100mw 780nm (10+x) PHR sled IR diodes and various DVD burners
>3.5watts ?904nm? (1x) C-mount, unknown manufacturer
150mw->500mw RGUV "White Laser" (3x) Custom Carbon Fiber Builds
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Old 06-25-2012, 04:10 AM #32
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Default Re: optical head with plexiglass frame

Very sweet build!
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405nm PHR-805T UniqueFire A10-B 100ma mogasm linear
405nm 600mw S06J C6 cree
445nm A140 1.35A 1.7W guidesman with G2
445nm 2.5W+ G-2 H1600 in a copper axis 1800ma Mogasm linear 2x AR16340's in a guidesman
445nm 9mm Blitzbuck V3 2.8A Saik 2.9W
445 800mw 9mm in a RHD MOD9 a pollished stainless auraura sh-032 667ma benboost
450nm Osram PL450 301mw in a powerlight B50 Host 400ma microboost
450nm Osram PLTB450 1.7W in a Bigboy Host 1650ma FMT driver
532nm 80mw DPSS DIY info to follow
532nm 50mw DPSS module LASERSMAN Freeby review to follow...
638nm mits300 671ma 500mw C6 cree
638nm mits500 WF-501B 1150mw
638nm mits500 C2 1450ma X-drive 1100mw
685nm 29ma mogasm linear 17mw C6 Cree Aurora
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