Pile of Aluminum transforms... to my new 2-3W RGBV Build

[mliptack]

Also the build took a few day halt, due to me getting sick. I'm just not feeling good etc... but I've got my Shipping and Receiving helper to take care of me

[mliptack]

Well this build keeps going... I got a Pat B (Laserman) dual 405nm combiner in a few days ago. I made a few modifications. Here you can see the two FlexMods or FlexDrives... I cant remember which is which... mounted on the back of the combiner. I used ceramic insulators there to isolate them from the aluminum along with a Nylon 6-32 screw.

Also there has been quite a bit of other progress being made... I have been spacing things out trying to figure out exactly how it is that I want to go about laying it out. While also trying to figure out my electrical paths.

When I build something this in depth, I have a tendency to want to engineer it *right* I want to think it through to make sure everything is done for a reason.

Also I am trying to figure out air circulation - I am going to encase the optics in acrylic... but I am still trying to find a good method to clean the filthy air. I would love to be able to use an electrostatic filter, but I am sure the noise 3-5KV would generate wouldn't be the greatest for galvos and other sensitive electronics... But I think my 12 60mm fans will move enough air to keep it cool

Here are some pictures of the Laserman combiner

[swamidog]

will you have sufficient thermal transfer through the ceramic insulators for decent heat sinking?

[mliptack]

I have always worried the same thing, but I have two rationalities. The ceramic pads are made for this purpose exactly. They actually have the hole drilled and everything. Second, the drivers will be only doing about 150-180mA. I haven't really settled on a current yet. In fact I am thinking about adding a TEC to cool the diodes to try to get a higher power. This just adds to the complexity.

The Flex Mod states it can be used to drive small current driven heaters... I wonder if this includes TECs... if so that could be useful. I could use one to drive the two diodes and the other to drive two small TECs. Anyone able to answer this?

EDIT: The FlexMod User Manual states that a heatsink isnt even required for the transistor under 250mA and the simple one provided would be adequate up to 500mA. However, I am sure with the ceramics, the air flow and the amount of aluminum in this beast I could probably drive diodes up to at least 3 amps.... if not the full six if I added a bit of arctic silver or other thermal paste to both sides of the ceramic pad.

[Doc]

Suck it and see

Just monitor the temerature under load, if all is well then fine if not; swap the ceramic for mica.

[mliptack]

I will monitor temp.... constantly... oooh I just let a cat turd out of the proverbial cat bag....

[danielbriggs]

Looking really good!

[mliptack]

Thanks, I'll have more to post in the next week or so. PLUS, I should be ordering new lasers in the near future (1-3 months). Looking at about 500-600mw of 640nm plus another 500mw of 658nm.

Hell I've gotta have some good reds to hold me off for another year or so until I can afford the blue