For your first build that will probably not happen tbh, your going to need some way of making enough space for battery + driver + switch + diode with module. It sounds fun but unless you'v built lasers before not very likely you'l endup with something that'l work. Thats not to say it can't be...
I got floaters too, their just a mild annoyance to be honest nothing to worry about too much. A blind spot AFAIK (regarding lasers) occurs when a high power beam hits your retina burning the light receptor cells in that spot. The damage is unrepairable so you basicly wont be able to see in that...
I would seriously recommend you dont leave the batteries in it and leave it turned off. 400mw of green = hell of a lot of IR. Always assume IR is being emitted even if you dont see any green.
From experience I would say rule out the most basic problems before you go ahead and do something...
Dw about the heatsinking too much. Try placing it into the pen host and it should light up when you put in batteries, just means it wont turn off till you take the batteries out.
You can add a button to the host itself, running a connection between the spring and battery connection.
Doubt it mate, you cant be sure the current is the same as needed by the red diode.
Buy a driver specifically for IR/red.
Also, be very careful with a IR laser.
Those look good, for the build your looking for they are a prime candidate :p
if you wanted to be on the safe side you could have fans blowing air through the fins, this would help your duty cycle a lot.
If you get the right diameter (12mm) you should be fine :D
If you look at the pic you can see the laser modules are in one giant heatsink, attached to a baseplate of solid metal. This is sufficient heatsinking for short duty cycles. For 1 hour continuous runtime you'd be looking to need some form of extra cooling, namely either TEC or fans. Finned...
Depends how many diodes and such you want, if your looking at combining more than a few, then knife edging would probably be a better choice price wise, because yes, only 2 beams can be used with polarizing cubes. Do some research on knife edging lasers, it should explain the bit about the...
IMO I'v been using a generic one off ebay..cost me about $15, and it does the job. If you have a bigger budget its probably best to get a temperature regulated one like ARG mentioned.
There is a "pot" that can be turned to change current. I'm pretty sure voltage will stay at 12V regardless of current.
Look just to the left of R2 , the first component on the left is the pot. I would suggest using a multimeter/ammeter to check the current while turning the pot. Can't...
Can only answer first question lol, knife edge arrays are mostly used for same wavelength combining, so if one was to want 5W of blue, they would usually use knife edge arrays to get that using indivudal blue diodes. Dichroic mirrors can be used to combine different wavelengths to achieve exotic...