Half-way unhijacking the thread: I'm having the same problem here. I'm running my PHR805 at 120mA through an acrylic lens. Focused to a tiny point, it won't light a match even if I color it black. It'll melt through electrical tape, but not much else. I've read on a few forums about how great glass lenses are for professional high-power builds, but would it really make much of a difference in my 120mA@70mw+-afew ?