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The " Sky Blue Ramjet" build

CDBEAM777

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The Sky Blue Ramjet - Electrons in....
Photons OUT !!


Time for another yet experimental build. See the pics. This one will be different from other experimental builds I have posted....as it will use mostly off-the-shelf parts.

I decided to use a very common, inexpensive, 2C Aluminum Maglite as a host. The black color - 2CCO16 Maglite Flashlight. Maglite makes a great product. Maglite's are solid built and all are side clicky. All Maglite's have a larger Bell head which lends itself to a reasonable diameter for additional corrective optics for beam shaping.

While this build is not in the Combiner Class...I suppose it could be called an "Aspect Corrected Optics class". I state this because the LD output will be corrected with a set of Telescope optics, being a Plano Concave Cylindrical lens and a Plano Convex Cylindrical lens. The magnification I use is 6X. These optics will perform aspect correction for a too-wide beam. The output will not be a perfect box....but close.

I also propose that this design could be used with other multi-mode wide beam diodes. I am sure this concept could be used to correct the Red P73 or Oclarro 63193 and possibly the Green 520 nm NDG 7475 and or the Blue 445nm NDB7A75.

The Sky Blue Ramjet build (SBR) will use one (1) NUBM07E ( @ 465 nm ) diode coupled with a G2 lens. I will use two (2) 25500 LiPo cells for power delivering a nominal 8.4 VDC to the driver. Current plan is to use the SXD-V8 4A fixed - Lazereer driver. I hope to achieve a output of 4.5 W....AFTER optical correction ! That is a beautiful amount of Sky Blue !!! Hopefully ...hammered into a tight beam !

With this build, there will be only one custom component: The Aluminum Heat Sink-Optical Platform insert (HSOP). See the drawing V8. I have started with a 2" ( 50.8mm)O.D. solid Aluminum rod stock ...which is now machined down to 3.189" (81mm) in length.

The Ally stock will be milled down to 48 mm in diameter... with a short portion left at 50.8 mm in diameter. This 50.8 mm ridge will be used as a lock area which will be captured by the original Bezel ring when it is screwed onto the Maglite bell front.
The back section of the unit will be machined down to 26.3 mm in diameter for placement within the bell recess pocket and will contain the CU module/LD and the driver. The LD will be press fit mounted in a CU Module and the module will eventually be set in a 12mm centered bore in the HSOP.

The most unique feature of the Heat Sink-Optical Platform insert ( HSOP ) is that it is home to all the major components...except the batteries and the I/O switch. The plan is to machine flat the front and back sections. The Front section will serve as the optical platform for the Cylindrical lens placement and the rear platform will serve as the mount flat for the driver.

The Cylindrical lenses will be epoxied to the front flat section and the driver will be set with Artic two component epoxy to the rear flat section.

As is typical, the CU module will capture/position the LD and the Collimation lens....which will then be inserted and secured with a set screw into the non-flat machined segment of the HSOP.

So...all the goodies ride on the Heat Sink-Optical Platform insert....including the V8 driver. A short portion of the HSOP will extend out past the bezel lock ring. I wish all optics would ride within the bell...alas....this cannot be... due the separation demanded between the cylindrical lenses.

I have attached pics of the start of the project. I am waiting on DTR/Lazereer for the NUBM07E diode. I really wanted to present a build....that may also serve as a obtainable and doable design for those wanting to enter the area of Aspect Corrected Optics class. This is especially desirable in that so many of our new, high power diodes are multimode...and will benefit greatly from corrective optics !! We can hammer the beam....from a thin bar....into a box/rectangle....where width....is only slightly greater than height !!

The attached pics are self explanatory...I just removed the components where the Xenon Bulb was mounted. With these components gone, the pic shows the host open top where the +/- hook-up points are located.

The thin metal tab extending up is the negative supply for the driver and the 6mm x 6mm metal square located in the centre of the recess is the switched positive supply for the drive. Very straight forward !! Driver gets connected to these points and the LD gets connected to the driver !!

While this host was designed for two (2) standard C cell batteries...the geometry of the 25500 LiPo is exactly the same...so no modification needed for the battery portion of the host !

SO....there you have it....This project started out some time ago as the " EZ-Adaptor "....which was an add-on for just the Cylindrical optics on to any handheld. Connectivity problems with that initial design where a roadblock. The SBR is a work-around....Enjoy the build..... and stay tuned !!!:na::na:
 

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CDBEAM777

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Additional Build Pics....

1) See below a pic of the first generation EZ Adaptor. This may help to visualize what the HSOP will be based upon. The semi-circular section extends out from the back section ... as a flat section on which the optics are attached. The HSOP builds on this concept and will be more complicated, but will cover several mount functions.
 

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jander6442

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Subscribed. Please add during the build where you will be acquiring the lenses please.
 

CDBEAM777

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Subscribed. Please add during the build where you will be acquiring the lenses please.
THAT is a problem. I have a China source....and I have tried them out !!!but....we must buy a decent quantity ( like 100 of each )to get the price down !!!! Typical problem !!

Edison offered the exact same lens I really like over at PL for $ 25 a set. ...and I have tried these. Not sure he has more....my stock is very low !!!

Perfect results with the Edison source or the China source !!!

Note the unusual geometry for the Plano Concave......I call it a scoop design...but....I really like this geometry....and I like the larger overall size.

A BIG question is....will the Cylindrical's offered by LSP work ??? Dunno ???
They are 4X....and they are a smaller lens. Theory sez they should work !!! ?? I have not tried them...and. I like a larger size for my big fingers !!!

I do not want to do a GB !!! Yikes !!! Not sure what the solution is ?????
But....it may be a problem we will have to face !!!

Let's see what interest this build generates...and that may provide some additional insight into this component supply !

BTW....your Dual 405 build was the inspiration for using a Maglite host for the Sky Blue Ramjet project !! Thanx !!!!!
 

CDBEAM777

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Well....we now know that the NUBM07E Sky Blue LD can be well corrected !! Currently doing optical experiments to determine the best placement of the lenses.

Also...the SXD V8 needs to be heat sinked...4 sure !!!....and the 07E needs the full Copper module back....for sure. I have made adjustments to the original HSOP design. The incorporation of the full Copper module back has given rise to a new placement for the driver.

Stay tuned for a drawing and progress pics as I machine the HSOP unit.:tinfoil::tinfoil::tinfoil::tinfoil::beer:

See a pic of my optics testing.
 

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CDBEAM777

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OK....a slight re-design of the HSOP unit. The NUBM07E must use the full body Copper module. The SXD V8 driver must be coupled to a good heat sink.

See drawing V12 attached.

To accomplish both these goals....I have relocated the driver to ride atop the Copper module...Piggy back style. So....The current version of the HSOP ...V12 can accommodate both the Full CU module and a proper heat sink for the driver....all contained within the HSOP V12 boundries !!!

Note: It is a real close fit for the driver to ride in that upper plenum area...real close....see u now the 6.16mm dimension....just with a .5mm room to spare between the driver edge and the ID radius of the host body!!! Sometimes....just sometimes...things work out good !!!
:beer::beer::beer::beer:

Now....to go from the CAD design....to the Machine Shop....:yh:
 

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CDBEAM777

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See you now some machining progress on the HSOP unit. We start with a 2" ( 50.8mm) diameter by 81mm long Aluminum rod stock. In every hunk of Aluminum...exits a heat sink !! Note the HSOP drawing in the previous post.

While an Aluminium Heat sink for a Maglite host is old news... The HSOP is a new twist..... for it will not only contain the Copper module housing the NUBM07E LD + G2 lens.....it will also act as a platform for the Cylindrical lenses demanded to correct the aspect ratio of this LD. (Read... correct the output from a bar....to almost a square).

The unit will also function as the heat sink for the SXD V8 driver. The driver will ride atop and parallel with the LD Copper module.

The HSOP ( Heat Sink Optical Platform ) is just a modified heat sink...but...this HSOP unit is pivotal to using a very common and obtainable high quality side clicky Maglite host to achieve a Optical Aspect ratio corrected
build.

IMNSHO....this amazing NUBM07E diode truly deserves this special treatment.
Stay tuned and watch this build unfold. See the attached machining pic's. Pic 7 shows just the HSOP at it's current state of completion.

The HSOP is not yet done...as the module 12mm bore and the flat sections are not yet machined....stay tuned for more build fun !!!! :beer::beer::beer:
 

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Pman

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I want to be like you when I grow up:) REP for sharing and encouragement.
Hate to see you work so hard on this and see so many posts with no comments. I appreciate what you do;)
 
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doubleone44

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^ Very true. I always enjoy seeing your builds and I like how you can tame any diode. I will rep you when I get to my computer :) you really deserve it and I think you help a lot of people with a better understanding of optics.
 

Gabe

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Awesome, I definitely want to see wow this project turns out, I love these diodes as well as your work. Any chance Terrawatt Labs is hiring? Haha jk, keep up the good work, and will rep when I can :)
 

CDBEAM777

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Pman, Doubleone44, Gabe, Thank you

I do have a passion for building !! The planning, CAD work....then the machining is so truly rewarding. All must work in union to arrive at some end build.

I hope and trust my passion for these projects clearly shows.

I must say...a most rewarding aspect has eluded me....that being a fellow member to copy my design.

Well either the design is not worth the effort....or the design's....before the Sky Blue Ramjet....have just been to complicated !

I dunno.....but.....with this build, a solution may be at hand !

Here is my hope....that the HSOP unit is really the only special piece one needs to accomplish a Aspect corrected hand held....( well....some Cylindrical lenses are needed too)

SO....I have been thinking...perhaps, just perhaps. I might offer that one piece....as a custom unit available for purchase. I have no computer driven machine faculity....just...as they say..."crankin the handles ! " So....these things take time !! Likely...eventually... four (4 ) hours to make one !....and the first unit is already at 4 hours....and likely...another hour or two to finish!! But....one learns as one goes along ....and with learning comes better efficiency / methods to reduce the machining time!!

Anyway...I am truly passionate about pushing our hobby to the limits that optics can offer.....and that is why I choose the Maglite as the base host !! The Maglite unit is a great deal at $20 bucks for a host. Rock solid...easy to buy at many places...and great quality !!! Add to that a good design that lends itself to adding optics to the front end...mmm....perfect as a base host !!

As a side note....all my future optically corrected HH builds....or Combiner units will use this exact same Maglite host....If at all possible !!!

Whew...lota words !! Aren't u glad you do not get charged by the word here !!:crackup::crackup::crackup::crackup:

Anyway....stay tuned...more build fun to come !!!:eg:

Note: A little glimpse of the future... A HSOP unit...with two (2) Copper modules....packed....side by side within the current HSOP geometry !!! Add combination optics and Cylindrical lenses....and.......just 10mm more in length !!!! Yikes....I have the design laid out !!!!
 
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CDBEAM777

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OK.....more machining pics.....The HSOP is basically done.....and it fits in the Maglite head in a solid fashion !

This was a bitch to machine....a lot of metal to remove....see the collection of chips in pic 14 !! Just takes time....for the irregular shape gives a challenge to holding the work piece while machining..Wah, Wah, Wah !:yabbem::yabbem:

Got 5 hours into this one....likely /hopefully, I will get that down to 4hr in future iterations ! We will see.

With the completion of this unit....we now need to populate the HSOP with the CU Module/LD and Artic epoxy down the driver. You can see in the pics the flat area for the driver ( smaller)....and the flat area for the placement of the Cylindrical lenses ( larger ). Finally we epoxy down the Cylindrical lenses....and that is it !!

Stay tuned as we head around the bend in the river ! :evil::evil::evil:
 

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Glutton

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Subscribed! Love your work. I plan on doing the same thing as far as taming this new 470nm diode in a hand held. This thread is definitely going to be a big help. Most likely going to need to contact someone on here who can do the machining on a custom host able to fit corrective optics. I know it's going to be well worth it tho especially for this beautiful wavelength!

Anyway, keep it up can't wait to see the final build and some pretty beam shots from this handheld! +1
 

CDBEAM777

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Subscribed! Love your work. I plan on doing the same thing as far as taming this new 470nm diode in a hand held. This thread is definitely going to be a big help. Most likely going to need to contact someone on here who can do the machining on a custom host able to fit corrective optics. I know it's going to be well worth it tho especially for this beautiful wavelength!

Anyway, keep it up can't wait to see the final build and some pretty beam shots from this handheld! +1
Well....Thanx Glutton! This diode deserves to be given special consideration !...like a Gold host !!

If you are considering a custom host, see this link for a compact corrected design...

http://laserpointerforums.com/f50/now-completed-optically-corrected-p73-hh-design-87235.html

But...these days...I want to make the possibility of having a Hand Held with corrective optics more accessible/affordable
....therefore the option of using a already great host.... coupled with a HSOP and optics.

The motivator here is 95 % to bring more members into the fold of owning a HH with advanced optical treatment ! Really...
4~5 hours of manual machining is no picnic ! I really luv to do machining work....but...once you remove the metal...well...there is no going back !!

Disclaimer... Optics have their limits...and do not make a perfect round beam....or deliver perfect alignment....but then...for our needs...these methods do make a drastic improvement......hence my new chant..." Hammer'in the Beam...into a Photonic Dream " hahaha..

As a side note, the Cyan Cannon project will now employ the Ramjet build protocol ( RBP ). And....will mix the
NUBM07E 470nm with the NDG 700 520nm LD.....Now...That will be a color we have not seen B4 ! SOooo many projects....I got'em stacked up for years.
 
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Glutton

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Wow I never should have taken a break from the hobby/forum I missed so many many amazing things. That dragons head looks so nice it makes my diode look like a flashlight!

If you don't mind me asking what are the focal lengths of those 2 cylindrical lenses you used to tame the red and what about the ones you plan to use to tame this new 470nm?
 




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