Hello Borislav. Thank you for the very well documented post. Excellent work.
1. Allow me to ask you, could you measure with a good degree of precision the dimention of the bundle of beams close to the laser (let say at 50cm from the module) and after that at 10 meters? This way we can extrapolate the divergence of the module without any collimation.
For example 4mm x 6mm at 50cm and 10mm x 15mm at 10 meters. Thank you very much in advance!
2. For maxing out the 500w module, you could buy a 1800w DC DC boost device. They go for about 15 USD in Aliexpress. Seem to be very stable at a maximum of 80mV ripple and 94-96% efficiency trough almost all the range (drops to 80% only when input voltage is as low as 12V...not your case)