Build thread: 4.4W 445nm dual diode laser

[JLSE]

Re: Concept: 4W corrected 445nm handheld

Yeah, I counted on inaccuracy's in my measurements so I added 5mm onto most area's so that space wont be a problem. It only made it 15mm longer, so why not.

Machining is being done by a company and I'm going to get a couple of different styles made. I wish I had the tools to make this myself :undecided:

Good, always leave yourself room.. With metal you can always take away,
but if there is not enough..... :gun:

It doesnt cost much for entry level tools, and its a great hobby. Not to mention
when you need parts for anything, you can make most with them.

Cant recall where in Canada you're located, but this is a great store, with
many locations from coast to coast > Busy Bee Tools Store Locations In Canada - Find A Tool Store Near You

 

[ARG]

Re: Concept: 4W corrected 445nm handheld

@offroad
That was the initial idea, if you read a bit further you'll see that that I said the 9mm diode have come out since and I am going to be using those.

@JLSE
Thanks! I'm on the west coast I never knew about this place glad to see there is some place in Canada selling mini lathes; I was considering a trip down to Harbor freight to pick one up, but the time/gas/boarder tax just isn't worth it. Is milling something that can be self taught from the internet? I've never used one.

 

[JLSE]

Re: Concept: 4W corrected 445nm handheld

Thanks! I'm on the west coast I never knew about this place glad to see there is some place in Canada selling mini lathes; I was considering a trip down to Harbor freight to pick one up, but the time/gas/boarder tax just isn't worth it. Is milling something that can be self taught from the internet? I've never used one.

I had never used a mill, but even back in high school, I took to the lathe like
second nature.. I can say the same of the mill.. Though like anything, time
and patience will get you far.

One of the hardest things is stay 10 steps ahead in your project.. For me that
idea took some adjusting, as I cut from the picture in my head. I take plenty
of measurements, but in full custom handhelds, I start with the raw material
and just 'go with it'.

Problems you run into can trash 10hrs of work. When this happens, not only do you have
to start again, but can take you out of the 'groove' and the next one doesn't come
out as nice.

Only recently have I started noting by drawings after something new.. This is
only to save time in the future without having to take certain measurements
again etc.

You get the hang of it.. A lathe is easy, when your workpiece is not centered
you notice by all the wobbling With a mill, you do not have the luxury of
a spinning workpiece. The fact that its stationary makes setup time a PITA.

To drill a nice smooth bore with a lathe takes me a few mins, to do the same with
my mill takes me much longer as there is much more involvement in squaring off the
workpiece to the endmill.

Setup is the most important and meticulous measurements are the biggest
factors in the outcome of a project.

If you decide to buy some tooling, PM or post which, and I can offer some advice.
I have bought quite a bit over the years from them...

 

[ARG]

Re: Concept: 4W corrected 445nm handheld

Okay, I actually looked into half wave plates, and they really aren't all that much consider how much this project has already run me.

Does anyone know how the light is polarized after a PBS? If I end up using one I think I'll have to use two sets of correction before the PBS.

@JLSE
It's something I will definitely be looking into after I have some more money to spend on hobbies. I have always wanted a lathe, even before the laser hobby. I enjoy metalworking quite a bit. Thanks for the offer and I will definitely ask for you advice once I start looking at tooling more in depth

 

[lazeristasUVISIR]

Re: Concept: 4W corrected 445nm handheld

Is milling something that can be self taught from the internet? I've never used one.

I read several books and I'm confident with a mill and a lathe The main rule - no rush. If you will be not using any exotic hard materials which dulls your tools quickly, it is an interesting hobby.

Your laser project - good luck. Don't burn too many curtains

 

[ARG]

Re: Concept: 4W corrected 445nm handheld

Your laser project - good luck. Don't burn too many curtains

Learned my lesson after I nearly set my wall on fire with my 300mW 532nm lab laser. Left it sitting on my table at the full 5V modulation while messing around with my DAC. I smelled smoke and turned around and the laser was burning a hole in my wall. I didn't think 300mW at 3 meters unfocused would do anything, boy was I wrong.

I made a makeshift beam stop after that

 

[ARG]

Re: Concept: 4W corrected 445nm handheld

Got more done for this project, now have working lens barrels for the 9mm diodes, and the HS/Host is being made. Ordered a PBS and waveplate, as well as some quality bounce mirrors designed for the blue spectrum. The bill for this all is stacking up fast

I decided to scrap the correction optics. They took up more space, and no matter what I tried I keep getting a ridiculous 12-15% power loss for the optics.

In the end I went back to my original plan. A waveplate and a PBS, so that I don't end up with an ugly "+" beam. I will save the correction optics for a single diode corrected build, a project for another day.

In the meantime, here's somthing for you all to look at :yh:

 

[Seoul_lasers]

Re: Concept: 4W corrected 445nm handheld

Looks like a promising project.

Just a little bit of concern regarding the heat transfer. For a high output dual laser module, like this, Copper is going to be your best friend. I might suggest some heat fins as well around the unit to keep the output as stable as possible.
Again, your project looks quite promising! Keep up the good work!

 

[ARG]

Re: Concept: 4W corrected 445nm handheld

Just a little bit of concern regarding the heat transfer. For a high output dual laser module, like this, Copper is going to be your best friend. I might suggest some heat fins as well around the unit to keep the output as stable as possible.

Copper isn't that much better than aluminium, it's not a huge difference; the modules are copper though. I also despise the brown look of copper, and the front part of the heat-sink will be seen. I wont be pushing the diodes either, I changed the plan up some more. I'm probably going to run each diode @ 1.9A so there wont be as much heat.

Again, your project looks quite promising! Keep up the good work!

.

Thanks!

 

[Cyparagon]

Re: Concept: 4W corrected 445nm handheld

Yeah, copper is the "go faster stripes" of the hobby

 

[Multimode]

Re: Concept: 4W corrected 445nm handheld

ArgLaser,

Looks good, the size and volume of the head looks massive compared to say a heatsink used in a C6 host.
So the cooling should be several times better even using Ali.
The Cu thing is unnecessary IMHO.
ATB
MM

 

[ped]

Re: Concept: 4W corrected 445nm handheld

Copper isn't that much better than aluminium, it's not a huge difference;

.

Thanks!

There are some that would disagree.

In that kind of build, every little helps.

 

[ARG]

Re: Concept: 4W corrected 445nm handheld

Copper is also harder to machine, and this host requires a lot of mill work. It's also more expensive (it both material and labour) and I've already spent to much on this build

 

[ped]

Re: Build: 4W 445nm handheld

^^ yeah I hear ya.

Iv'e heard its a bitch to machine.

But this is an epic build, and I'd be throwing every last cent at it haha.

 

[Cyparagon]

Re: Build: 4W 445nm handheld

You're looking at the number wrong. Sure, one is twice the conductivity of the other, but they're already both very high. Take the reciprocal and you have thermal resistance. It's like comparing a 2mΩ battery spring contact with a 1mΩ battery spring contact. You'll see zero performance difference between the two.

 

[benmwv]

Re: Build: 4W 445nm handheld

On a finned heatsink with a fan, sure the difference between aluminum and copper isnt that pronounced, but in a closed host copper is far superior. It has a much larger thermal capacity which means much longer duty cycles. Aluminum is just too light.