The tinkerer inside me won out, and I ordered a NUBM44 to test the relative cutting power versus the M140 and NDB7875. I ordered a couple of DTR's projector optics kits, should be able to cobble together a half decent beam expander. There's an 18mm lens with a 13mm focal length that looks decent for getting a nice, small spot. Have some knife edge arrays handy, but I'm not sure if I'm going to boby OutputCoupler - Laser Cutter Working Group
Can you get a 0.1mm spot out of the 6W diodes? DTR suggested that they had poor beam characteristics for laser cutting. I haven't looked into it, but I'm assuming the 3.5W diodes (NUB7A75? Pretty sure my 7875 tops out around 3W, don't have an LPM to check) are unpolarized, so using a PBS cube wouldn't work for combining beams. Can you get good results with a knife edge array, or does that screwby OutputCoupler - Laser Cutter Working Group
I'm planning to build a laser cutter, but I'm having trouble finding guidelines on how much power/power density is needed to cut various materials. I know this is going to vary significantly, but I figure there's probably some ballpark information out there. I've got some high power diodes from other projects, an M140 and NDB7875 (the older one, not the better 7A75), and decent enough optics. Thby OutputCoupler - Laser Cutter Working Group