So here's why I've decided to definitely not use violet:
405nm: .450W
532nm: .110W
658nm: .350W
84.3 lumens, .910W
445nm: .080W
532nm: .100W
658nm: .350W
79.2 lumens, .530W
Cut the laser power output by over 1/3, save the power on my green, and barely lose any lumens. Add in the cost like you mention, and blue is definitely in, violet is out.
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Now, the red debate:
445nm: .080W
532nm: .100W
658nm: .350W
79.2 lumens, .530W
445nm: .120W
532nm: .150W
638nm: .220W
122.9 lumens, .490W Holy crap what a difference! A reasonable number for the green, but a ~$200 investment for the red diode in order to increase lumens by 50% while simultaneously reducing light power output.
445nm: .150W
532nm: .185W
638nm: .265W
150.8 lumens, .600W Very nice, pushing the green a bit harder, but close to double the lumens of the highest lumens the 658nm configuration I can get! A risky configuration for the green module I have, but a risk worth it?
445nm: .210W
532nm: .245W
638nm: .350W
199.8 lumens, .805W Wow, 200 lumens out of this tiny thing, IF I can find a module like DjHeadie did for the green, but that's ANOTHER ~$200(?) investment.
I think the extra $200 for the red is worth it to me, it'll increase the lumens so much to go from 658 to 638nm, and simultaneously should increase battery life and put out less laser power for the same amount of visibility. Color rendition should improve as well.
But the extra money to find a better green module? That one I don't know about. Anybody got a green module that'll go into the heatsink and do 250mW of green light that they want to sell me directly? Heck, I've got a nice 12x violet diode, working and in an Aixiz housing, I'll trade you for a 250mW green module. What current draw does it take to get that kind of green power output from modules that people have currently?