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Zaser Custom XL Version 445nm 9mm 4.9W With Modified Hercules Beam Expander !!!

Minamoto Kobayashi

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Aug 25, 2010
Messages
532
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Here I'm again, with another crazy project :p
Finally I ended a project that I started at the beginning of this year.
As usually, I have spent a lot of moneys. This time, not for killed diodes, but to adapt a beam expander to the Zaser
head. The lenses was also a big problem: the power was so terrificant and concentrated in a very small line that have
melted the coating of one of the beam expander lenses.
But now, let's start from the beginning!
This is a Zaser black anodized custom version. It has a slighty bigger head (in diameter) and has one more fin:

lnSfUp.jpg


This is the head of the Zaser.
With the help of an handmade reamer, I have carefully removed the unneeded black anodized part inside the diode
hole, to assure a better heat transfer between ther copper heatsink and the aluminum head:

H8ZVO4.jpg


This is the special custom pill. Mrcrouse has made for me a rock solid and well built special pill for my Zaser, because
I needed a solid surface to put the driver, with good heat dissipation:

2lstAs.jpg


zHWoRw.jpg


The Nichia 445 nm diode 3.5W in full copper heatsink with X-Drive @3.5A:

StLU2S.jpg


The driver placed inside the custom pill and glued with alumina thermal compound:

TpcFX0.jpg

EIncpf.jpg


Diode and pill+driver in the right place (the pill is locked in the head thru a thin threaded ring which pushes the pill
against the inner end of the head):

5VZ8fP.jpg


The other spring in the tail cap part:

WZYvaG.jpg


A piece of acetate foil to eliminate any battery rattle inside the host:

mKK6YP.jpg


All the pieces ready to be assembled.
All the three lenses of the Laserglow Hercules Beam Expander was unmounted, decoated and recoated with a new
custom filter frequency range (from 440 to 460 nm), and reassembled:

mC4q80.jpg


The creature assembled and mounted in a small high-quality Manfrotto tripod+clamp:

9MFHFf.jpg


The performance graph without the beam expander:

4zNxoS.jpg


.. and with the beam expander. There is a loss of power of about 600 mW:

uvF0gy.jpg


Shots in the night sky (10 sec exposure, sorry for the fuzzy photos and the different beam color, but only the
laser had the tripod, not the camera):

dmnegh.jpg


sJd1jv.jpg


And now, the demonstration of the terrific injuries of a 4.3W diode output power collimated to a very tiny point.
I used a 80 grams sheet with a light green color:



Conclusions:

this is not an handheld, this is a scary weapon!
Even shot against the white plaster ceiling of my room the laser leaves a nasty black mark.
From my room window to the garden entrance there are about 70 meters.
If I point the laser against a dry leaf resting on the asphalt near the entrance, the leaf starts
to smoke and then transforms into embers!
Anyway I'm very satisfied of the final result!
To realize this project, I sacrificed some items, such as one lens and another beam expander.
As a sort of bonus, I want to bring knowledge to another variant of this build.
Initially it was my intention to use a special beam expander built from two different expanders: a piece from
Laserglow Hercules Beam Expander and the main body from the Jetlaser Beam Expander.
Those were the nice results:

wn3dos.jpg


9njjGm.jpg


pDElcm.jpg


UjbOWH.jpg


L1A8TD.jpg


Unluckly, the Jetlaser beam expander had a very long focus, so I was unable to focus a collimated beam
even at 10 meters away from the aperture.
Thus, the handheld appears to be very unbalanced toward the beam expander.
It was a pity, because this beam expander is built very well, it is cheap, and the lenses
accept also the 445 nm frequency without the need of recoating.
However, with the last solution, I obtained a well balanced handheld with a big range focus.
And since I have two fine regulations (the 405 G-2 lens barrel original focus regulation and the Laserglow
beam expander regulation), I can vary either the input and the output beam, so I have the choice to have
a precise millimetric range from short to middle, or from middle to infinity :p

And now, as usually, I wish to thanks a lot:

- Mr. Jordan of DTR shop for his quality evergreen diodes, drivers and lenses;
- Mrcrouse for his professional craftmanship and the ability to solve every issue and to satisfy every strange requests;
- Laserglow for its moddables beam expanders;
- Marco Bottaro from Outlet Glasses Company (Italy) for the professional decoating and recoating procedure;
- The walls of my room ... :crackup::crackup::crackup:

Other crazy projects are coming in my dirty mind, stay tuned 'till the end of this year. :beer:

Kisses to everyone!
Richard.
 
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DTR

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Awesome work. One correction though it is a 3.5A driver not a 2.4A driver. Anyway great build. Thanks for posting.:beer:
 

jdawg

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Nice Laser! :drool: :gj:

I've been thinking of doing something with the same diode. Were there any other hosts you considered using before picking? Also, by ramping up the current, do you think you could've reached 5.5W?
 

Sigurthr

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Beautiful piece of equipment you have there! Be careful with it though, I set my curtains on fire years ago with a 1200mW blue!
 

upaa27

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Love the correction optics at the end! Good job.

+rep
 

Minamoto Kobayashi

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Nice Laser! :drool: :gj:

I've been thinking of doing something with the same diode. Were there any other hosts you considered using before picking? Also, by ramping up the current, do you think you could've reached 5.5W?

I think that Ricktrent could have some nice builds for You :p
 

jdawg

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:drool: that's magnificent. What duty cycle do you estimate for it?
 

Minamoto Kobayashi

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After one minute the Zaser is slightly warm and I shut off it for safety. I think that during the cold seasons I can reach 2 minutes.
 

djQUAN

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nice. I like the integrated beam expander :)

how is the dot at long range? is it still a flat bar/rectangle or now a little more round?
 

Minamoto Kobayashi

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The beam expander vary only the dimension of the dot, not the shape. For example, if You focus at 10 meters, the line will be 1/10 of the original size (without the beam expander), but it is still a line. With a tremendous burning power. Focusing at 100 meters You will have the same dimension of the line that You can see at 10 meters without beam expander. And so on ...
 
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Minamoto Kobayashi

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Aug 25, 2010
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Laser harp :D

eg1ohH.jpg


(from left to right: Cypreus XL gold plated 1.7W 462nm, Optotronic 500 532nm, Zaser XL 4.3W 445nm.
 

IWIRE

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Beautiful build ! As always, exquisite attention to detail. I really enjoy your build threads. Great work adapting the beam expander. Bonus points for that ! You have a good eye for what a finished product will transform into. Can't wait to see what you come up with next ! I bet if it ain't a 10 it's a 9.9 :)
 

Minamoto Kobayashi

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Lol :thanks: a lot for Your kindly words.
I have three threads to do: the 4W c-mount red stubby build (if Lazereer does the miracle before the end of the world :crackup:), the 1.4W 520nm Zaser XL polished version, and the video for my custom build rotating platform for rotating beams :beer:
 

IWIRE

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Lol :thanks: a lot for Your kindly words.
I have three threads to do: the 4W c-mount red stubby build (if Lazereer does the miracle before the end of the world :crackup:), the 1.4W 520nm Zaser XL polished version, and the video for my custom build rotating platform for rotating beams :beer:
Your more than welcome. Thank you for sharing your builds ! Ok, the rotating platform/rotating beam thingy has my interest peaked. I'll be keeping a look out for that one ! :beer:
 




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