My 1x18650 2w build

AutoItKing · Apr 13, 2012

Hey all.
I've set out to create a 2W 445nm laser using only a single 18650!
I know it's possible and I'm almost certain someone has done it before, but I like building things so there.

Host: TR-801 (eBay)

Diode: H1600 from DTR
Driver: 2x BenBoost (830mA+955mA) from cilegray

Still need: Custom heatsink
Where can I get a copper heat sink made? I know some members on here do it! PM me if you can!

This is not my first laser. I built a 1W 445 last year, but never finished it. My diode decided to take a crap.

And yes, I have eye protection!

RyanElectro · Apr 13, 2012

And great job with a dual driver setup, 1x18650 builds are very promising and have much higher capacities than 2x16340. I'm going to be building a few of these myself, but I don't plan to use dual drivers

As for heatsinks, check out Eudamonium, he has heatsinks at great prices, and your best bet if your in Europe. Jayrob will be able to make some high quality ones too, but last time I approached him about it, he didn't seem too keen to make me one, so I'm not too sure.

AutoItKing · Apr 13, 2012

My roommate (justinjja) got a heatsink from him, but he doesn't do copper. And I need as much heat capacity as I can get!

lman · Apr 13, 2012

AutoItKing said:
My roommate (justinjja) got a heatsink from him, but he doesn't do copper. And I need as much heat capacity as I can get!

Aluminum dispersises heat quicker.

RyanElectro · Apr 13, 2012

Oh justinjja is your roommate? haha that's pretty awesome!

You honestly don't really need a copper heatsink. You're much better off with a copper module instead (cheaper too). There's a GB going on right now you could take advantage of:
http://laserpointerforums.com/f55/gb-2-copper-modules-all-sizes-73507.html

lman · Apr 13, 2012

You need 5.6mm

532 with Envy · Apr 14, 2012

Those are some great host's! You may have problems fitting two drivers in there though. You'll have to drill out the center section if there is any chance. These are really better fit for a single flex drive and what heatsink you do fit in there may not be able to handle 2W.

Talk to mohrenber, he still may have some of these heatsinks, I had him make mine for the same host's.

AutoItKing · Apr 14, 2012

532 with Envy said:
Those are some great host's! You may have problems fitting two drivers in there though. You'll have to drill out the center section if there is any chance. These are really better fit for a single flex drive and what heatsink you do fit in there may not be able to handle 2W.

Talk to mohrenber, he still may have some of these heatsinks, I had him make mine for the same host's.

That's why I want copper!

This f***er's gonna get hot!
I'll PM him and see. I might get a custom one that extends out a little further to make room for a driver and extra heat sinking. We'll see when I get the host.

Oh and there's plenty of room for two BenBoosts (they're tiny!)

532 with Envy · Apr 14, 2012

Also you may want to check up on combining two drivers with different settings. I know in discussions of linking two flex drives they both had to be set at the same mA or there where problems.

This may not pertain to the Benboost's though.

Good luck, keep us posted with beam shots :beer:

AutoItKing · Apr 14, 2012

532 with Envy said:
Also you may want to check up on combining two drivers with different settings. I know in discussions of linking two flex drives they both had to be set at the same mA or there where problems.

This may not pertain to the Benboost's though.

Good luck, keep us posted with beam shots :beer:

Should work just fine since they're current sources. They follow whatever voltage they need to. AFAIK
If there is an issue I'll set them both to 888 and deal with not getting 2w.

tsteele93 · Apr 14, 2012

lman said:
Aluminum dispersises heat quicker.

This is much debated and highly suspect.

Your best bet is finned copper, but copper is going to be a better choice than aluminum in any circumstance except cost, workability and perhaps looks of you don't like Cu.

Eudaimonium · Apr 14, 2012

AutoItKing said:
My roommate (justinjja) got a heatsink from him, but he doesn't do copper. And I need as much heat capacity as I can get!

Correct, I have no means of obtaining copper bar stock at the moment. At least, not for cheap as I get aluminium.

Thanks for endorsement, Ryan!

Oh and, the debate wether copper is better, I believe y'all refered to this thread but nobody posted a link:
http://laserpointerforums.com/f54/i-want-copper-copper-copper-well-maybe-not-72698.html

AutoItKing · Apr 15, 2012

Eudaimonium said:
Correct, I have no means of obtaining copper bar stock at the moment. At least, not for cheap as I get aluminium.

Thanks for endorsement, Ryan!

Oh and, the debate wether copper is better, I believe y'all refered to this thread but nobody posted a link:
http://laserpointerforums.com/f54/i-want-copper-copper-copper-well-maybe-not-72698.html

What if I were to send you copper???

oke:

Since my host is so small, I think I want both my module and heat sink to be copper and then thermal it to the host so it can dissipate the heat. Yes it will get hot, but I knew that already! Unless a alu heatsink really is better.

I'll PM you when I get my host and some dimensions.

Eudaimonium · Apr 15, 2012

Obtaining copper is not the only problem - I also don't have means of machining it.

Sorry man, but I can honestly do only aluminium. I could make you a direct pressfit heatsink for that host no problems.

Regardless if heatsink material, I would strongly advise against trying to cram out 2W out of a diode in such a small host. Duty cycle will be very short, no matter if heatsink is aluminium, copper or brass or whatever. There's just not enough room.

AutoItKing · Apr 16, 2012

Look what I got!

Compared to my WF-502B (10W, 1000lm)

LED: (not that anyone cares lol)

Driver:

LED's Gone:

Driver side:

Ready for laser!

Heatsink:

Full size

Also, I did test fit a BenBoost and I can fit two in the driver space. It'll be tight and wiring is gonna be a pain... but just watch!

Eudaimonium · Apr 16, 2012

Largest diameter being 19-something milimeter, I doubt I can make a set screw for that.

I'll ask if some improvisation is possible, but I doubt it. Have a back up plan just in case.

My 1x18650 2w build

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