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The “ TRIDENTIS ”…… 6.7 Watts of Blue Beauty !
This project was technically and morally supported by Jordan at DTR. His feedback and help were of great valve. The supply of the 445nm - 9mm modules was of pivotal importance, as these are the heart of the “ Tridentis ”…a Hand Held, three (3) 445nm-9mm LD units driven at 2.1A@, knife edge combined and optically corrected delivering a total beam propagation pumping out about 6.7 Watts !
The concept was driven by the goal of using off-the-shelf components whenever possible. The use of mass produced parts has a cost advantage and incorporates proven technology. I used my projector building experience, limited as it is, to provide a framework for the design.
The unit has a combined output of 6.68 W. The main heatsink weighs in at 1.3lbs alone. The dimensions are 224mm long by 63mm in diameter (at the head end). This is NOT a pocket pointer. If the LiPo’s run dry…the unit would make a dandy Nut Cracker!! The collimation lenses in the modules are the “ Stock” lens offered by DTR. Each DTR 445 module contains an X-Drive set at 2.1A.
I considered Copper for the main heat sink, but instead used the arrangement from most CPU coolers- CU directly in contact with the heat source (DTR module design) and then Aluminum to move and dissipate the heat to atmosphere. I considered Peltier and fan cooling, but, although technically possible, really overkill for the intermittent I/O cycle of a HH…besides….that mass of Aluminum will move a very large amount of heat away from the diodes.
There are many ways to increase PO and/or apparent brightness;
• Overdrive the LD…and lower the life.
• Increase the optical efficiency…typically a higher divergence underwrites increased PO.
• Increase the heatsink mass/surface area or TE/ liquid cool the LD.
• Optically combine multiple LD’s.
• Minimize the beam profile to achieve maximum beam density.
• Select the wavelength closest to peak eye sensitivity of 555nm.
The “ Tridentis” uses beam combining via knife edging, nothing new there, but challenging in a very compact HH format. The beams are combined and aligned by using prism mirrors coupled to slightly modified Flexmounts. Again, off the shelf, stable and fully adjustable known art.
LD1, the main beam, is aligned with the unit C/L axis …LD2 and LD3 are in a separate module holder which is rotated 90 degree to join LD1 from the side… via the angled prism mirrors. The three (3) combined beams then enter a pair of Anamorphic Prisms to correct the astigmatism of the 445 LD’s. While Anamorphic Prism’s do not fully correct the beam astigmatism…. they lower the farfield divergence to a great degree. When the three (3) beams are combined/stacked… a fairly square geometry is delivered. The Anamorphic Prism’s and the Knife Edge Prism mirrors are all AR coated for the 445nm line.
As close to square as possible farfield geometry was a goal for me …such a delivery is both aesthetically desirable and packs the beam density within a symmetric shape. In addition, the lower the divergence, the greater the beam density (mw/c2) becomes….which in turn provides the greatest apparent brightness. Again, nothing new, prior art applied to a Hand Held format.
I decided to use the “off the shelf host” – the “Skyray 6000LM”. This unit houses four (4) 18650 LiPo cells. The host body has a side push button I/O and I added a DPST micro switch for safety….a safety/enable switch to “ ARM” the unit. When this switch is in the “on” position, an LED indicator flashes "green" within the acrylic base of the anamorphic prism mount. This indicator visually announces that the unit can now be turned on….SOooo….get your eye protection on NOW!!!!!! Only when the arm switch is in the “ON” position, can the I/O switch turn the Lasers on.
The Skyray 6000LM is an Aluminum unit of very good quality for fit and finish and was quite adaptable. The host has a screw in internal bulkhead plate to which the main Aluminum heat sink is secured with a single ¼-20 bolt. The host body had to be machined down in length and the battery compartment arrangement had to be modified so that two (2) 18650 cells are combined to deliver 7.4 VDC power and then combined in a tandem configuration of four (4) cells.
Throughout the build…the philosophies of “use what is available and build on those existing benefits” were my guides. There is NO doubt that the other multi-diode Hand Held units have a much more “ Finished “ look …and more features….but….well…I was aiming for that “ Functional/Steam punk “ appearance !!!
Some Build notes…
There were three components whose dimensions were definite; The LD modules, the Anamorphic corrective prism’s and the knife edge prism mirrors. The design was dictated by these items and by the selection of host. The host selection was governed by what power source / battery configuration would drive the three (3) LD modules.
The first component that was designed and built was the double knife edge prism mirror unit. This unit used the off the shelf- Flexmount (LSP) for the prism mirrors (Lasertack). The flexmount’s required modification both in the height and length dimension. Building in flexibility is both good and bad…good to achieve the optimal alignment…and bad….because…the more adjustability…the more things can loosen and become out of alignment!!...BUT without adjustability, optimal alignment and maximum beam density cannot be done!
With the dual knife edge assembly done, I next choose the design for the main heat sink. The inspiration for a semi-circle extended platform for the optics came from ARG.(Thanx!) The main heat sink design was also governed by which host is used. I ended up with the SkyRay 6000LM. As it turns out….this was a very good choice for there is an internal screw-in plate / bulkhead to which the Main Aluminum heat sink is secured.
The alignment procedure is demanding….but made easy by the use of the Flexmount units. First…the radial orientation of all the LD’s must occur. The near field propagation MUST present to the Anamorphic prism’s with the slow axis in a vertical position for the anamorphic prism’s to work…for all three (3) LD’s. When this is complete, LD1 is the master. Its beam is completely set for pitch and yaw by the bore thru hole in the main heat sink. It cannot be adjusted…other than radial fashion and along the bore axis. LD2 is adjusted, via the first knife edge unit to be brought into alignment to LD1. LD3 is then adjusted to be in correct alignment with the combined beams of LD1 and LD2. All adjustments are done to arrive at an optimal presentation in the farfield.
Finally, the wiring…!!! All silicon wire ( Flaminpyro). Two (2) switches: Safety/arm switch to indicate the unit is armed and can be energized and the main I/O switch. Four (4) 18650 3400 mAh LiPo cells sit in the modified Skyray battery compartment. Runtime ~ unknown…likely 15-20 min total.
This type of project requires the use of CAD, End Mill and Lathe use to design and bring the concept to life. The “ Tridentis” is NOT for sale… nor will be. It was my desire to design and build a proof of concept, using my prior knowledge and existing off the shelf components to deliver the final product. I acknowledge the amazing work of JLSE, ARG, Multimode, Blord, DTR, Jayrob, Eudaimonium,and many others for their component supply, input and inspiration. Thank you.
For a brief moment….the “Tridentis” is the “ King of the Hill “ in the visible spectrum for PO…..but, I am sure it will be a short time before the next inspired creation will zip by this and claim the title. The real take away is to demonstrate what is possible and…” Be happy in your work” !!!
LPF has such a great spirit and excitement for ALL things associated with Coherent Light. This pervasive enthusiasm is a very welcome and inspirational attribute!!! Many times… members of LPF present products on the leading edge…products which can be used for the HH format and in the projector area. I am thankful for that and read BOTH LPF and PL daily. Thanx for reading. Hope you enjoyed my creation. As you may suspect, I have been working on this project for quite some time….but…it has been a real “ Labor of Love “…Now…on to a quad or Hex design ….!! DARPA has nothing on us !!
See the Pics !!
I am working to get beam shots !! TOOooo bright !!!
CDBEAM
This project was technically and morally supported by Jordan at DTR. His feedback and help were of great valve. The supply of the 445nm - 9mm modules was of pivotal importance, as these are the heart of the “ Tridentis ”…a Hand Held, three (3) 445nm-9mm LD units driven at 2.1A@, knife edge combined and optically corrected delivering a total beam propagation pumping out about 6.7 Watts !
The concept was driven by the goal of using off-the-shelf components whenever possible. The use of mass produced parts has a cost advantage and incorporates proven technology. I used my projector building experience, limited as it is, to provide a framework for the design.
The unit has a combined output of 6.68 W. The main heatsink weighs in at 1.3lbs alone. The dimensions are 224mm long by 63mm in diameter (at the head end). This is NOT a pocket pointer. If the LiPo’s run dry…the unit would make a dandy Nut Cracker!! The collimation lenses in the modules are the “ Stock” lens offered by DTR. Each DTR 445 module contains an X-Drive set at 2.1A.
I considered Copper for the main heat sink, but instead used the arrangement from most CPU coolers- CU directly in contact with the heat source (DTR module design) and then Aluminum to move and dissipate the heat to atmosphere. I considered Peltier and fan cooling, but, although technically possible, really overkill for the intermittent I/O cycle of a HH…besides….that mass of Aluminum will move a very large amount of heat away from the diodes.
There are many ways to increase PO and/or apparent brightness;
• Overdrive the LD…and lower the life.
• Increase the optical efficiency…typically a higher divergence underwrites increased PO.
• Increase the heatsink mass/surface area or TE/ liquid cool the LD.
• Optically combine multiple LD’s.
• Minimize the beam profile to achieve maximum beam density.
• Select the wavelength closest to peak eye sensitivity of 555nm.
The “ Tridentis” uses beam combining via knife edging, nothing new there, but challenging in a very compact HH format. The beams are combined and aligned by using prism mirrors coupled to slightly modified Flexmounts. Again, off the shelf, stable and fully adjustable known art.
LD1, the main beam, is aligned with the unit C/L axis …LD2 and LD3 are in a separate module holder which is rotated 90 degree to join LD1 from the side… via the angled prism mirrors. The three (3) combined beams then enter a pair of Anamorphic Prisms to correct the astigmatism of the 445 LD’s. While Anamorphic Prism’s do not fully correct the beam astigmatism…. they lower the farfield divergence to a great degree. When the three (3) beams are combined/stacked… a fairly square geometry is delivered. The Anamorphic Prism’s and the Knife Edge Prism mirrors are all AR coated for the 445nm line.
As close to square as possible farfield geometry was a goal for me …such a delivery is both aesthetically desirable and packs the beam density within a symmetric shape. In addition, the lower the divergence, the greater the beam density (mw/c2) becomes….which in turn provides the greatest apparent brightness. Again, nothing new, prior art applied to a Hand Held format.
I decided to use the “off the shelf host” – the “Skyray 6000LM”. This unit houses four (4) 18650 LiPo cells. The host body has a side push button I/O and I added a DPST micro switch for safety….a safety/enable switch to “ ARM” the unit. When this switch is in the “on” position, an LED indicator flashes "green" within the acrylic base of the anamorphic prism mount. This indicator visually announces that the unit can now be turned on….SOooo….get your eye protection on NOW!!!!!! Only when the arm switch is in the “ON” position, can the I/O switch turn the Lasers on.
The Skyray 6000LM is an Aluminum unit of very good quality for fit and finish and was quite adaptable. The host has a screw in internal bulkhead plate to which the main Aluminum heat sink is secured with a single ¼-20 bolt. The host body had to be machined down in length and the battery compartment arrangement had to be modified so that two (2) 18650 cells are combined to deliver 7.4 VDC power and then combined in a tandem configuration of four (4) cells.
Throughout the build…the philosophies of “use what is available and build on those existing benefits” were my guides. There is NO doubt that the other multi-diode Hand Held units have a much more “ Finished “ look …and more features….but….well…I was aiming for that “ Functional/Steam punk “ appearance !!!
Some Build notes…
There were three components whose dimensions were definite; The LD modules, the Anamorphic corrective prism’s and the knife edge prism mirrors. The design was dictated by these items and by the selection of host. The host selection was governed by what power source / battery configuration would drive the three (3) LD modules.
The first component that was designed and built was the double knife edge prism mirror unit. This unit used the off the shelf- Flexmount (LSP) for the prism mirrors (Lasertack). The flexmount’s required modification both in the height and length dimension. Building in flexibility is both good and bad…good to achieve the optimal alignment…and bad….because…the more adjustability…the more things can loosen and become out of alignment!!...BUT without adjustability, optimal alignment and maximum beam density cannot be done!
With the dual knife edge assembly done, I next choose the design for the main heat sink. The inspiration for a semi-circle extended platform for the optics came from ARG.(Thanx!) The main heat sink design was also governed by which host is used. I ended up with the SkyRay 6000LM. As it turns out….this was a very good choice for there is an internal screw-in plate / bulkhead to which the Main Aluminum heat sink is secured.
The alignment procedure is demanding….but made easy by the use of the Flexmount units. First…the radial orientation of all the LD’s must occur. The near field propagation MUST present to the Anamorphic prism’s with the slow axis in a vertical position for the anamorphic prism’s to work…for all three (3) LD’s. When this is complete, LD1 is the master. Its beam is completely set for pitch and yaw by the bore thru hole in the main heat sink. It cannot be adjusted…other than radial fashion and along the bore axis. LD2 is adjusted, via the first knife edge unit to be brought into alignment to LD1. LD3 is then adjusted to be in correct alignment with the combined beams of LD1 and LD2. All adjustments are done to arrive at an optimal presentation in the farfield.
Finally, the wiring…!!! All silicon wire ( Flaminpyro). Two (2) switches: Safety/arm switch to indicate the unit is armed and can be energized and the main I/O switch. Four (4) 18650 3400 mAh LiPo cells sit in the modified Skyray battery compartment. Runtime ~ unknown…likely 15-20 min total.
This type of project requires the use of CAD, End Mill and Lathe use to design and bring the concept to life. The “ Tridentis” is NOT for sale… nor will be. It was my desire to design and build a proof of concept, using my prior knowledge and existing off the shelf components to deliver the final product. I acknowledge the amazing work of JLSE, ARG, Multimode, Blord, DTR, Jayrob, Eudaimonium,and many others for their component supply, input and inspiration. Thank you.
For a brief moment….the “Tridentis” is the “ King of the Hill “ in the visible spectrum for PO…..but, I am sure it will be a short time before the next inspired creation will zip by this and claim the title. The real take away is to demonstrate what is possible and…” Be happy in your work” !!!
LPF has such a great spirit and excitement for ALL things associated with Coherent Light. This pervasive enthusiasm is a very welcome and inspirational attribute!!! Many times… members of LPF present products on the leading edge…products which can be used for the HH format and in the projector area. I am thankful for that and read BOTH LPF and PL daily. Thanx for reading. Hope you enjoyed my creation. As you may suspect, I have been working on this project for quite some time….but…it has been a real “ Labor of Love “…Now…on to a quad or Hex design ….!! DARPA has nothing on us !!
See the Pics !!
I am working to get beam shots !! TOOooo bright !!!
CDBEAM
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) into the this amazing unit. Congratulations on finally getting her up and running. I know it has been a long road but there is nothing like the feeling when finishing a project like this.:beer:
