hi ely,
this may help with your question about IR light. it is an answer sent to me from DaGuin, he does alot with bluray and has given my excellent service on the ones i got from him. i dont know if blurays are his specialty but he sure knows about them. you may have seen his posts in the bluray section of the forums and elsewhere. this is informative and should be posted permanantly on the forum, imo. blurays dont emit ir as i understand but you definitly dont want one in the eye so get proper protection.
daguin:
"There are no green "diodes" commercially available yet. Plus the ones that are just coming online to the industry are FAR below the outputs we want. Although they are working hard on them, high powered green diodes are still a ways off. What you have seen are green "modules." The "modules" you see are DPSS modules. DPSS stands for Diode Pumped Solid State. How they work is that there is an Infra-Red diode "pumping" IR light through a second set of crystals that "double" the frequency of the IR light to make it 532nm. That is why people are concerned with IR filters on green lasers. Some of the IR light "leaks." This is the same process used in yellow (593nm) lasers and blue (473nm) lasers. The crystal sets used to get the yellow and blue are even less efficient. That's why yellow and blue lasers are so expensive and have low outputs. Neither red nor violet diodes produce Infra-Red light so no filters are needed.
You will VERY RARELY find a hobbyist building a green laser from scratch because it takes machine-level tolerances in spacing and alignment to get the crystals to lase. Occasionally, someone will buy a surplus crystal set or mounting and try it, but it is almost unheard of because it is expensive and the odds against success are very large. People will buy a complete "module" to install in a host, but that is not the same as building one. Very high powered modules are sometimes available, but they are a very large gamble, both for output and stability. High powered greens are very unstable because as the components heat up, the expansion alters the spacing and alignment.
This crystal "doubling" is very inefficient. Most of the pointer type green lasers use a 500mW IR diode to get less than 100mW of green light. Most of the cheaper higher powered green lasers use a 1W IR diode to get above 100mW of green. In order to get the type of output that my RPL is capable of requires a 2.5W IR diode. It also requires a very high degree of precision in alignment to get these outputs. When you add on the extra problems of making it acceptably stable in a hand held unit and the process is daunting indeed. There are higher outputs available in "lab-style" lasers, but they have large PSU's and required active (usually TEC) cooling and mains power. "