DIY Diode housings

[danielbriggs]

By the way, the aixiz module is ever so slightly tapered. It varies from about 11.80mm up to close to 12.00mm along the length, so just something to watch out for if you're after good thermal contact.

Also, I've been machining heatsinks for diodes which completely do away with the aixiz module, i.e. the diode is a press fit into a chunk of aluminium. The standard acrylic or aixiz lens just screws in to the front. With a small blob of thermal paste around the diode, the whole setup has an exceedingly good 'thermal capacity' which can handle high power diodes, keeping them cool.
The heatsink designs were previously made to fit portable handheld style lasers, so I didn't bother posting about them as I knew they wouldn't be of interest, but they could easily be adapted to the 'module' style, with the diode beam at a standard height for projectors etc...

As soon as I've got a spare weekend, I've got this idea of using an aluminium/copper hybrid heatsink for the really toasty diodes. It will be a solid copper core with the diode directly mounted to and the lens screws into the middle, then the copper assembly will press into an aluminium finned shape to provide extra cooling.

Here's a link to some of the portable heatsinks currently in production:
http://danielbriggs.co.uk/laser/index.html



I've got my own CNC miller and a lathe in the garage at home, so if anyone has anything in mind they want whipping up, drop me a PM

Apologies for the mini-thread jack

Cheers,
Dan

[Frixxion]

By the way, the aixiz module is ever so slightly tapered. It varies from about 11.80mm up to close to 12.00mm along the length, so just something to watch out for if you're after good thermal contact....

I have measured mine and it is 11.9 mm, so I'll just put it in a 12 mm bore and add alot of thermal paste :P

[QUAZAR]

I wouls still like to see someone make something similar to this.



Square section blocks are far easier to mount compared to round diode mounts. A small flange on each side with mounting holes would be preferable to the holes underneath. Threaded at the fromt for a screw in lens assembly and costing about £15 should tick all the boxes.

[danielbriggs]

I have measured mine and it is 11.9 mm, so I'll just put it in a 12 mm bore and add alot of thermal paste :P

If you're boring it, you could get the exact fit with the cutter. But if you are drilling it, you may want to think about adding a small set screw, as a 12mm drill will create a hole larger than 12.00mm due to it's geometry, so may be too loose on it's own.

Dan

[danielbriggs]

I wouls still like to see someone make something similar to this.
<snip>
Square section blocks are far easier to mount compared to round diode mounts. A small flange on each side with mounting holes would be preferable to the holes underneath. Threaded at the fromt for a screw in lens assembly and costing about £15 should tick all the boxes.

I don't think that will be a problem to make.
However, from a fabrication point of view, making it cylindrical with a flat on the bottom, would be easier. On the base could be 2 tapped holes, which a plate attaches onto to give you your mounting flange.

I need to make myself something very similar, but a bit more elaborate for the 2x reds and 2x 405's I'm making for my projector over the next few weeks. So I'll post my creations, and we can sort something out if you're interested.

Cheers,
Dan

[Frixxion]

If you're boring it, you could get the exact fit with the cutter. But if you are drilling it, you may want to think about adding a small set screw, as a 12mm drill will create a hole larger than 12.00mm due to it's geometry, so may be too loose on it's own.

Dan

That's what I thought off, I have made a small m4 set screw in my design.

Anyways I didn't have to work yesterday so I didn't get the chance to mill out my design.... I'll probably be able to make it next week and then I'll post some images

[Frixxion]

Ok, this is what I came up with. I think it is within my capabilities to make this with the tools that we have at work. Let me know what you think about it.

I'll probably have 3 of these done by tomorrow afternoon so I'll post pics of the real deal by then.

[mikkojay]

That is a dandy design- I like it. It looks like it would lend itself to simpler machining too. Please post some pics when you get some made!
-Mike

[Frixxion]

Got the first one done ! I think they look hot! . And they work perfect! The module fits in smoothly and is held tightly when the bolt is tightend




The two on the right are only partially done but I'll finish those up next week .

[mikkojay]

Nicely done!