Achieving a smaller beam diameter with 803T optics

The beam to my Sonar Laser is about 4mm thick, not that great. I read up on Igort's lens thread on how spherical lenses have an extremely small focal point, which is when I started to experiment with some lenses I had. This tutorial is really easy to follow, and will have you with a 1mm beam in less than 10 minutes!
Things you need:
•Violet laser diode in Aixiz module
•Lens nut for Aixiz module
•PHR-803T sled
•Patience and creativity

Let's get started, shall we?

Step 1: We need to take out the old Aixiz module lens. To do this, I just took a small screwdriver and popped out the back of the AixiZ module. Now, take out the lens in the Aixiz module. It should easily slide out.

Left: Aixiz lens nut with back popped off. Right: Aixiz lens nut with lens out. Note that I made the hole a little bigger on the back of the Aixiz lens nut, you will need to do so to get your spherical lens out without scratching the back.

Step 2: Get the PHR-803T sled and take off the spherical lens at the front of the sled. You need to carefully sand the circumference of the lens, so it is a little smaller in diameter.

Left: After  Right: Before

Step 3: Place the lens (with spherical side out) inside the back of the Aixiz module lens nut. You can use a small screwdriver to push the lens in from the sides.


Step 4: Place the back of the Aixiz module lens nut onto the Aixiz module nut, with the spherical side of the lens out.

Left: After the mod. Right: Before the mod.

And you're done!
Here are some pictures of the results (Left and right, different cameras) (Two matches were lit to bring out the beam)

Before, With lights:

Before, With little light:

After, With lights:

After, With little light:

The results are breathtaking. If you want a serious beam, then you have to do this mod! The original lens is good for burning, as spherical lenses are not perfect. Although this mod will give you a paper-thin beam, it will also give you this!

The dot is still tiny, but there is lots of scatter around the beam. I still think it's worth it, though  

Re: Achieving smaller beam with the PHR-803T!

awesome! i will have to try this!

Re: Achieving smaller beam with the PHR-803T!

Wow, awsome! Really good for beamshots, but my first laser will probably be for burning. And isn't 160mA a little much? Considering you've already broken four. ;D And what host did you use?

Re: Achieving smaller beam with the PHR-803T!

randomlugia said:

Wow, awsome! Really good for beamshots, but my first laser will probably be for burning. And isn't 160mA a little much? Considering you've already broken four.  ;D And what host did you use?

Click to expand...

I used the Sonar case and Heatsink made from Dark_Horse a while ago. It was originally 105mA, but for whatever reason it jumped up to 160  . No clue why. Oh, and those four broke from various reasons other than too much current :'(.

Re: Achieving a smaller beam diameter with 803T op

Well I've fallen at the first hurdle. I can't for the life of me get the back off the lens nut :-/

Re: Achieving a smaller beam diameter with 803T op

I think those lenses are designed to produce concentric circles within the beam, which is why you get that strange looking distortion and scatter

Re: Achieving a smaller beam diameter with 803T op

12dstring said:

Well I've fallen at the first hurdle. I can't for the life of me get the back off the lens nut :-/

Click to expand...

Hmm, really?
I tried it with two of my lens nut and both of them popped off. On one of them the lens fell right out.
Try this:
Use an eyeglass screwdriver, and stick it inside the hole, and bend the screwdriver backwards. If it helps, put the lens nut backwards inside of an Aixiz module.

rkcstr said:

I think those lenses are designed to produce concentric circles within the beam, which is why you get that strange looking distortion and scatter

Click to expand...

Interesting.. Thanks for the info.

Re: Achieving a smaller beam diameter with 803T op

Excellent mod! I just tried this with one of my blurays. The beam is much narrower and more visible, but with some scatter and artifacts (concentric circle effect). I like the narrow, more visible beam. Burning is no problem, mine easily focussed to a tiny dot a few inches in front of the laser. It cut black tape. A wooden match with a white head ignited instantly. No burning problems here. I'll have to try this with a red and the spherical lens from a 20x dvd burner. As I tried this mod, I also took two of the lenses that are found inside the sled and (since their focal length is too long alone) I stacked them inside an Aixiz lens nut. This stacking of two lenses shortens the focal length enough that I could collimate for distance or burning. Great, now I can use the lenses from inside the sleds too. Glad I kept all the optics from each sled that I took apart for the diode.

12dstring : That lens nut ring gave me a tough time too. Every time I tried to pry as shown above, the plastic just split. Finally I grabbed an edge with very small needle nose pliers and it came out. I threw it away and used a small o-ring to hold my spherical lens in the aixiz lens nut. I think that some of these lens nut rings must be a much tighter press fit than others.

Re: Achieving a smaller beam diameter with 803T op

i wish i could try this but i have no Sled

Re: Achieving a smaller beam diameter with 803T op

Can you please draw or take a close photo of what a spherical lens looks like (shape).
thanks.

Re: Achieving a smaller beam diameter with 803T op


No problem.
Post 555 with 5 rep

Re: Achieving a smaller beam diameter with 803T op

also do you leave the original lens in the nut or do you take it out?

Re: Achieving a smaller beam diameter with 803T op

carulli said:

also do you leave the original lens in the nut or do you take it out?

Click to expand...

You take out the original lens, so the PHR lens is the only lens in there.

Re: Achieving a smaller beam diameter with 803T op

Sweet mod!!!
I'm gonna go try it right now!

Re: Achieving a smaller beam diameter with 803T op

I put the spherical lens in my lens holder and put it on my X100, and it focuses it to a point about 5cm from the aperture. Works better than the collaminating lens from NOVA!  

I've got to try this when I build one. (Or attempt.  )

Someone needs to do this with a 4x build.
EDIT: Well, since AMK is apparently doing a group buy for 12x's...

Re: Achieving a smaller beam diameter with 803T op

Would this reduce power? Is the opening getting smaller, or just a better lense?