Hey everyone,
I have finished my 520nm Sanwu Pocket build! There were some pretty big challenges that were overcome during the build. Firstly, due to the super small size of the pocket series host, I needed the most efficient high power 520nm diode I could find, from all of the diodes I could find it seemed like the NDG7475 would be the best. It may seem like a waste to put such a powerful diode in a small host and only give it 1A but in hosts this small, efficiency is too important.
The second major issue was the module needed for the pocket host, a standard 12mm module wouldn't work. I contacted sanwu to see if they had any pocket series modules that they were testing 9mm diodes in, they told me that they didn't and that it couldn't be done. I didn't my own measurements and found that the best way to do it would to be design a new module and get it machined for me. Luckily the member trinh hong phuoc was able to find the problems with my design and machine me a module! Trinh realy is the hero here, he(I assume) did so much work translating my terrible handwriting and bad design ideas, he even made me custom press tools for the module without me asking for them. I wouldn't expect this kind of service is a machine shop in the USA, if you have any custom work needs, ask trinh.
For the diver I used the ACS1500SE, this turned jut to be a mistake for a few reasons. The driver is slightly longer than the data sheet showed, I had to sand it down a lot and it still was a bit too long. EDIT: it turns out that this driver couldn't handle the 1A load, I ended up changing the driver to a flexdrive and am getting 1A easily.
I also had to shorten the lens barrel from the G8 lens to fit the pocket series host. I removed the lens from the barrel and cut about a 3rd of the barrel off, then reinstalled the lens. At first, I had thought that I had damaged the lens after trying it with me 405nm pocket series laser, it turns out that the threads on the 405nm module were a bit loose and were causing the lens to be slanted. On the custom module that trinh made had no such problems. One problem the module does have (this was my fault) is that the focus adapter from the pocket host will not screw down completely flush, I designed the front side of the module to be a bit too long, one day I will sand it down but I am worried about getting dust on the diode window.
After a bit of struggle I got everything put together and, WOW! This thing is so bright for how small it is. Even in a bright room the beam is clearly visible. I am extremely happy with this build. It ebend up costing more than I was planning but I'm not too worried since this buold was such a success.
I want too thank the members of the forums who put up with my nooby questions. These include DTR, Miya, lifetime, GSS, Paul, Red Cowboy and of course Trinh. I am sure that I forgot someone but know that I appreciate your help.
link to the custom module post.
I have finished my 520nm Sanwu Pocket build! There were some pretty big challenges that were overcome during the build. Firstly, due to the super small size of the pocket series host, I needed the most efficient high power 520nm diode I could find, from all of the diodes I could find it seemed like the NDG7475 would be the best. It may seem like a waste to put such a powerful diode in a small host and only give it 1A but in hosts this small, efficiency is too important.
The second major issue was the module needed for the pocket host, a standard 12mm module wouldn't work. I contacted sanwu to see if they had any pocket series modules that they were testing 9mm diodes in, they told me that they didn't and that it couldn't be done. I didn't my own measurements and found that the best way to do it would to be design a new module and get it machined for me. Luckily the member trinh hong phuoc was able to find the problems with my design and machine me a module! Trinh realy is the hero here, he(I assume) did so much work translating my terrible handwriting and bad design ideas, he even made me custom press tools for the module without me asking for them. I wouldn't expect this kind of service is a machine shop in the USA, if you have any custom work needs, ask trinh.
For the diver I used the ACS1500SE, this turned jut to be a mistake for a few reasons. The driver is slightly longer than the data sheet showed, I had to sand it down a lot and it still was a bit too long. EDIT: it turns out that this driver couldn't handle the 1A load, I ended up changing the driver to a flexdrive and am getting 1A easily.
I also had to shorten the lens barrel from the G8 lens to fit the pocket series host. I removed the lens from the barrel and cut about a 3rd of the barrel off, then reinstalled the lens. At first, I had thought that I had damaged the lens after trying it with me 405nm pocket series laser, it turns out that the threads on the 405nm module were a bit loose and were causing the lens to be slanted. On the custom module that trinh made had no such problems. One problem the module does have (this was my fault) is that the focus adapter from the pocket host will not screw down completely flush, I designed the front side of the module to be a bit too long, one day I will sand it down but I am worried about getting dust on the diode window.
After a bit of struggle I got everything put together and, WOW! This thing is so bright for how small it is. Even in a bright room the beam is clearly visible. I am extremely happy with this build. It ebend up costing more than I was planning but I'm not too worried since this buold was such a success.
I want too thank the members of the forums who put up with my nooby questions. These include DTR, Miya, lifetime, GSS, Paul, Red Cowboy and of course Trinh. I am sure that I forgot someone but know that I appreciate your help.
link to the custom module post.
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I love it when someones plans works out and they figure out the bugs!
