Blue Tetra-beam Titanium/Copper build

Another Qualas build, this time using a Nubb24t submodule.

The Fan shaped beams were fun, but what about going parallel for this build?

Build summary:
- Unsoldered the submodule from the Nichia module, I kept the original lens array this time
- Reflowed the 4 LD’s submodule in a 20mm DTP Copper board
- Installed on a Convoy S21G copper head titanium body
- Added a plastic ring for isolation followed by an 1/4” copper spacer, pressed with a copper shim + thermal compound
- Tapped another 1/4” slightly bigger cooper spacer with 11.5mm threads and fitted an glass window
- Bezel holds everything sandwiched together

For power I’m not using a Polyboost here, as the voltage needed was ~15.5v after warmup, I modified the Vout divider of the Convoy 12v 2.5a driver to make the MP3431 top at a theoretical 15.54v (right below its max 16v)

If the diodes are really cool, this just works as a CV driver until the Vf drops bellow the threshold, then it will regulate on CC mode at the 2.5a sensed by the shunt/op-amp.
I decided to not modify the current as this would put the booster IC way past its thermal rating.

Things gets interesting with an expander, the threads to attach them were the biggest goal for this project

The 93 grams of copper that sink the heat of this thing for some seconds before it’s too hot to hold

Also a comparison with my purple twins and a Survival Laser C6 host.

You've really gotten a taste for it, haven't you?

Paulostool said:

The 93 grams of copper that sink the heat of this thing for some seconds before it’s too hot to hold

Also a comparison with my purple twins and a Survival Laser C6 host.

Click to expand...

I was about to say a S21G wouldn't have enough mass for how much power you're putting into that array. That was the problem I ran into with S2+ builds I did touch 9W+ but had to keep duty low to allow for cooling. That's a Monoheatsink or MHS is what I called my design coming in at 57.5 grams of pure copper and can only handle about 15W of wasted heat for 1 minute on and 2.5-5 min off

Darktron said:

I was about to say a S21G wouldn't have enough mass for how much power you're putting into that array. That was the problem I ran into with S2+ builds I did touch 9W+ but had to keep duty low to allow for cooling. That's a Monoheatsink or MHS is what I called my design coming in at 57.5 grams of pure copper and can only handle about 15W of wasted heat for 1 minute on and 2.5-5 min off

Click to expand...

Nice monoheatsink!
This should match really good with the cooper S2’s! How is it fixed?

I have some high powered builds on Convoy S2’s: (and a lot more in the >2W range)
- Nubm0C @5.8A on a smooth copper S2+
- GH04C06V9G @6.2A on aluminum S2

Both are using the full DTR 20mm copper module and solid back + copper pill.
The solid back of the modules were pressed with a copper sheet jacked and thermal compound hold by the pill.
The front on the modules are able to just screw in over the opening and still make full contact between diode and back half!! (With thermal compound on final build)

It gets pretty packed with cooper and very heavy!
Also features a cute short mode using a 18350.

Those build images are from the tests with a brass pill before drilling the copper one.

Paulostool said:

Nice monoheatsink!
This should match really good with the cooper S2’s! How is it fixed?

I have some high powered builds on Convoy S2’s: (and a lot more in the >2W range)
- Nubm0C @5.8A on a smooth copper S2+
- GH04C06V9G @6.2A on aluminum S2

Both are using the full DTR 20mm copper module and solid back + copper pill.
The solid back of the modules were pressed with a copper sheet jacked and thermal compound hold by the pill.
The front on the modules are able to just screw in over the opening and still make full contact between diode and back half!! (With thermal compound on final build)

It gets pretty packed with cooper and very heavy!
Also features a cute short mode using a 18350.

Those build images are from the tests with a brass pill before drilling the copper one.

Click to expand...

Really nice builds I got 9.5W or so 5A rated driver NUBM0F this one is S8 but is same design slightly longer. Is a full copper side and back (LD base) with just a slot for the wires very similar design similar to the LD banks. I do use thermal paste between the LD base and heatsink since I don't like it being solder to the heatsink. The reason why I say 15W excess heat is because you shouldn't include the full driver output just what is wasted into heat due to inefficiency in parts. Is a slug design so if I ever just want to change host color I can do that easily as fast as changing a battery (is not fixed but held by the battery tube). I did try 18350 and it was a bit tight but it did fit just didn't look good because I could see a little bit of a thread. But yeah the trick is that you need efficient LD to avoid pumping in so much heat into these small hosts once you step into array levels like yours you'd want more mass for sure.

Even cooler with a 5x expander!

Thanks @Z80 Lasers!