Laserdiode heatsink array

Development of heat sink array for laser diode characterisation (April 2018):

One of my first small scale project at the National Physical Laboratory was the development of a heat sink array for laser diode testing. The device was requested by a scientist who needed to incorporate a system to measure multiple laser diode on his optical measurement bench. Once I had gathered and agree with all requirements, I have proposed two different concept designs with technical drawings. I raised an initial quotation enquiry to our manufacturing department. Due to the limited budget, one concept was chosen, and I decided to reduce the manufacturing cost by substituting CNC metal parts by 3D printed components. To determine which of the parts could be suitable for a substitution, I developed a heat transfer FE model to compute a worst-case scenario, were the laser diode is reaching its maximum operating temperature. I compared the case of a system made of aluminium and copper parts with one having parts made of polycarbonates or other polymers. Using additive manufacturing allowed to decrease the lead time and cost of the overall system from £3,000 to £1,500. The design was thought to accommodate laser diodes with different pin packages, by having an easy access to swap cables and connectors without disassembling the whole structure. Once assembled and delivered, I followed up with the scientist to ensure the system was performing as desired.