Well, that's very nice of you planters. It seems apparent these days that the more minds that we have on a project, the more gets accomplished. Take the 638 "Grail" project. It's all but perfect now. Or, rather it is perfect. On the subject of 532, Z folds and V folds sound interesting and all, but imho the simpler-is-better approach holds for me. Anything that decreases parts count, cost, alignment issues etc seems better. I'm thinking that a lot of research and parts-hunting is going to be the first challenge. I like Steve's idea about cooling the xtal in liquid. Toxic doesn't sound all that great tho lol. If we could find a larger KTP/YV04 xtal instead of the tiny ones found in most of the smaller 532 equipment such as was in my vid, it would be a start, right? You deal with several optics companies directly .. maybe ask them for sources? .. I'll keep looking on the internet for hybrid crystal companies. What size xtal do you think would work? 5x5x3mm I believe I read will output about 1 watt . Maybe something larger than that may be needed.
--edit-- I was typing when you posted, meatball... do you have any suggestions for said problem?