445nm 1W
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This is a project to create a 1 watt 445nm laser, using a diode from a Casio XJ-A140 projector in an Aurora 18650 host.
Project Status and Updates
- 6.21.2010
- Initial plan drawn up on whiteboard
- Dorcy main body segment modeled in Autodesk Inventor
- 6.23.2010
- Dorcy flashlight button segment modeled in Autodesk Inventor
- Dorcy flashlight assembly created in Autodesk Inventor
- 7.6.2010
- Class 4 warning sticker made and ordered from Zazzle
- 7.8.2010
- Plan changed, decided to use a much smaller 18650 host
- Initial plan for new driver started
- ATtiny24 selected as controlling MCU, for size and I/O requirements
- 7.9.2010
- PCB for driver started, found feasible
- Design for driver started in WEBENCH online tools using LM3410
- Multiple power modes tested using Op-Amp MOSFET driver
- 7.11.2010
- Schematics and part selection complete, PCB routing begun
- 7.14.2010
- 7.17.2010
- Prototype PCB routed, coding begun
- 7.23.2010
- LM3410 samples received
- Prototype built using sample IC, SB350 diode, 1.5uH inductor (pulled from Dell motherboard), and 9.5/18uF ceramic capacitors
- Limited testing done at operating point of ~600mA output and ~4V battery voltage, LM3410 IC dissipates significant power, output appears to be clean with minimal overshoot during startup and no inductive spike at shutdown.
- 7.25.2010
- Testing done at ~300mA with probe set to 10x, ringing and current ripple around 50-80% of full scale
- Versadrive project abandoned due to poor/unsafe performance
- Micro BoostDrive ordered
- 7.31.2010
- Aixiz module and Micro BoostDrive received
- Laser assembled, initial testing done, on-hand batteries found insufficient at drive current of 1200mA
- AW 18650 battery ordered from Lighthound
- 8.7.2010
- Heatsink cut to size and attached to Micro BoostDrive to prevent overheating, found semi-effective
- 8.11.2010
- Micro FlexDrive v5 ordered to provide greater current output
- 8.12.2010
- Micro FlexDrive v5 order cancelled due to no stock
- 1.7.2011
- Power decreased on Micro BoostDrive to reduce heat, continuous runtime increased to ~1 minute, 29 seconds, still capable of igniting cardboard
Videos
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Project Cost Breakdown
Component | Cost | Source | Status |
445nm1W XJ-A140 Diode | $38.50 | Group Buy - kiyoukan | Alive, in use |
Aurora SH-032 18650 Host | $21.62 | Dealextreme | In use |
Aixiz Module | $3.39 | HighTechDealz | In use |
Custom Copper Heatsink for Aurora Host | $40.00 | jayrob | In use |
Aixiz 445nm Glass Lens | $11.00 | jayrob | In use |
AW 2600mAh 18650 Protected Li-Ion Battery | $18.78 | Lighthound | In use |
Micro BoostDrive | $26.00 | Micro BoostDrive | Alive, in use |
Total Price | $159.29 | Price final |