The more I play with it the worse focus it seem to have, I must had the lens at an angle before to get “good” aim at 10feet because I think I finally have it now the burn focus is about 4 inches from the pointer. At 10 feet I get a huge circle showing all the dust on lens and glare ring . I need a new tip assembly, lens or both to get this focus the way I want.
I doubt what you want is ever going to actually happen--you can maybe get closer to it but ....
You can modify/shape the output with lenses and loss of power but only to an extent --- you can not fundamentally change what it is at the source.
All lasers exhibit divergence--divergence is never zero ---there never has been a laser either DPSS or direct diode the starts at 5mm wide and is 5mm at infinity--even the best beam quality DPSS laser which are much more "perfect" than any diode laser ever can be.
Typical divergence is 1mm per meter of distance.
You can see the divergence spec on the Osram data sheet for your diode--last page here: http://www.semicomvisual.com/wp-content/uploads/2016/02/PLT5-510.pdf
It can never be any better than that.
If you designed something that needs that, you are SOL due to not understanding the nature lasers in the real world.
See Alaskan's comment in post #10 here: https://laserpointerforums.com/f49/laser-diode-chip-aperture-lens-aperture-wavelength-relationships-divergence-92977.html
"Even with low divergence single mode diodes, after leaving the facet the beam will spread very fast and after a few millimeters will quickly become much wider, but you can focus it down, how small? Depends on a lot of factors. I've never tried to calculate that because I am not interested in cutting lasers, only low divergence collimated lasers. I just did a google search and you can find more info that way as well as some here, but someone might be willing to crunch some numbers for you to see if what you want is possible. Most members expect a full forum search as well as a google search first, but I don't mind helping some, here's a thread relating to your question regarding beam spot size: https://laserpointerforums.com/f38/how-focus-405nm-laser-diode-small-round-spot-81383.html "