Custom Heat Sink (request for quote)

Jubathoph · Jun 13, 2011

Hello everybody,

I have designed a custom heat sink, and now need to find someone to fabricate! I know there are a lot of really good machinists on this forum so I wanted to see if anyone here can help me. Please see the attached drawing pdf. and picture of what I am talking about.

I think this should be no problem for anyone with a lathe, however the one catch is that the portion that is threaded (for custom lens) is an odd size of M 12x0.5. I do have a source for this thread if someone is interested.

Let me know what you think and if this design can be improved.

Design notes:

Material is 6061 Aluminum. This will fit inside the end portion of my Ultrafire WF-501B host, with the end portion exposed to the air, resulting in good heat dissipation. I have found a special "plug" which fits on the pins of the diode, so I don't need to solder to those pins.

Thanks and regards,

-J

rhd · Jun 13, 2011

Very impressive request for quote - makes me wish I had a lathe just so that I could help you with it.

Jubathoph · Jun 13, 2011

Thanks, I'm trying to be as specific as possible. I also have access to Solidworks, which really helps draw this up.

Xtrm2Rick · Jun 14, 2011

Jubathoph said:
Hello everybody,

I have designed a custom heat sink, and now need to find someone to fabricate! I know there are a lot of really good machinists on this forum so I wanted to see if anyone here can help me. Please see the attached drawing pdf. and picture of what I am talking about.

I think this should be no problem for anyone with a lathe, however the one catch is that the portion that is threaded (for custom lens) is an odd size of M 12x0.5. I do have a source for this thread if someone is interested.

Let me know what you think and if this design can be improved.

Design notes:

Material is 6061 Aluminum. This will fit inside the end portion of my Ultrafire WF-501B host, with the end portion exposed to the air, resulting in good heat dissipation. I have found a special "plug" which fits on the pins of the diode, so I don't need to solder to those pins.

Thanks and regards,

-J

if that is what im thinking it is....diode socket....white plastic with brass pins?

carefull with those things, they killed allot of diodes

Asherz · Jun 14, 2011

How will you press fit the diode inside the heatsink? You'll need to make sure that gap is big enough behind the diode to fit the rear end of an aixiz module so you can press fit the diode in properly.

Edit:

As to forum machinists, theres Ehgemus, ray j neal and I think Wannaburn has a lathe but not sure if he does commission work.

Kevlar · Jun 14, 2011

Check with eudaimonium or pontiacg5. Those are the two that come to mind right now but there are several others. Good luck!!

Oh, and as Rick stated, be carefull with those "diode sockets" (if thats what your planning).

Eudaimonium · Jun 14, 2011

I see you want to use Ultrafire WF-501B...

As a matter of fact, final heatsinks are just being machined as we speak to finally ship of to Radiant so they will be stocked and sold there.

Check this out, dual component heatsink:

I'm about to make a thread, for those new direct pressfit heatsinks (along with Cree C6 ones).

I am not sure that using a diode socket is a good idea. Actually it's a terrible idea.
Why would you want that?

Also, why M12 ? Standard Aixiz lens is M9, and metal nuts from these lenses can be taken apart and accomodate your custom optics...

In short, I'm M12 tap short of being able to machine what you're asking me.

I can, however, provide alternatives.

Jubathoph · Jun 14, 2011

To be clear there is no diode socket here, I'm not even sure what that is. just aluminum and the diode for this baby! It doesn't make much sense to put an insulator like plastic between the heat source and heat sink, does it. The reason I need a M12 is because I am using a much larger lense than the standard 9mm. This bad boy has an 8mm clear aperture and a longer focal length of 8mm. I expect a 2x improvement in divergence from this lense hence the experiment.

As for the press fit, is aixiz the best way to go? I figured since I am not using their module there's no point for using their diode press. But it may be the best way to go, you tell me.

rhd · Jun 14, 2011

Jubathoph said:
To be clear there is no diode socket here,

"plug", "socket"

Tomato, tomato.

Whatever you call it, it's a really bad idea.

Jubathoph · Jun 14, 2011

Right, it was never part of the plan so let's move on! Thanks for all the input so far.

Jubathoph · Jun 14, 2011

Those are great looking heatsinks. The M12x0.5 tap can be found on Amazon for $15, I would cover this cost.

I wanted to avoid the Aixiz + heatsink in order to elliminate the added thermal resistance between having two surfaces in contact. I figure if you make a custom heatsink make it all one piece.

Eudaimonium · Jun 14, 2011

Ofcourse, that's why I do the direct pressfit heatsinks in the first place. I am not much fond of Aixiz housings too, and much less cutting the set screws to lenght

If you have 2x better divergence, you have 2x wider beam. Not sure why exactly do you want that in a handheld laser, I'd understand if it were a laboratory setup.

Anyhow if you want you can somehow get the special tap you want to me, I'd make the heatsink for $15. Just remember that I'm in Croatia so if you're in a hurry you may want to speak to someone closer to you.

Jubathoph · Jun 14, 2011

@ Eudaimonium, Asherz brought up a good point about how to press fit the diode. Is it standard to use the back end of the Aixiz, and if so, how wide does the access hole need to be?

Thanks

Eudaimonium · Jun 14, 2011

Yeah you can use the back end of Aixiz to press it, though it's more of an improvised solution rather then widely accepted one.

Still, it works.

Now, what kind of diode and lens do you plan on using so that it requires such non-standard setup?

Jubathoph · Jun 14, 2011

Whats the best way? I'm using a 445 with thorlabs A240, see my post in Optics about large aspheric lense.

Jubathoph · Jun 14, 2011

BTW I have the lense already and unoficial tests look really good. I will post results as soon as I can get it built

Custom Heat Sink (request for quote)

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