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Laser Flashlight Hack!!

by Kipkay on August 6, 2007

Table of Contents

License: No license (full copyright) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Intro: Laser Flashlight Hack!! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

step 1: What you need... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

step 2: And... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

step 3: Extract the DVD Laser Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 4: Extract the Laser Diode.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 5: Continue extraction... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 6: The new DVD Laser Diode! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

step 7: Preparing the AixiZ housing... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

step 8: Assembling the housing... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

step 9: Installing it in your MiniMag! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

step 10: Final Step!! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

step 11: Test it out!! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

step 12: FAQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

http://www.instructables.com/id/Laser-Flashlight-Hack!!/
License: No license (full copyright)
Intro: Laser Flashlight Hack!!
Turn a MiniMag flashlight into a powerful DVD laser pointer! This 245mw laser is powerful and fits real cozy in a MiniMag! See the video at the end for the Test Results!

NOTE: This Instructable WILL NOT WORK with any CD burner/player diodes or DVD player diodes!

See the FAQ on the last Step for common questions

GET THE BURNING LASER DIODE HERE!

GET THE MINI-MAG FLASHLIGHT HERE

UPDATE: If you want to use this as more than just a novelty item, a driver circuit is recommended. See the schematic for details.

Disclaimer: CAUTION! As you know...lasers can be dangerous. Never point them at any living object!T his is not a toy, and this should not be used like a conventional
laser pointer. In other words, don't use it in presentations, or to play with pets, or allow children to use it. It should only be operated by responsible persons who
understand and respect the potential laser safety hazards.

http://www.instructables.com/id/Laser-Flashlight-Hack!!/
step 1: What you need...
You will need the following items:
1. 16X DVD Burner. I used an LG burner I had as a spare.

or...

You can buy the Red LASER DIODE HERE

step 2: And...
2. A Mini-Mag Flashlight You can get one HERE

3. An AixiZ Laser Module. You can get one HERE

4. Small jewelers screwdrivers, X-Acto knife, metal snips, drill, round file and other small tools.

Image Notes
1. 650nm 5mw 12mm X 30mm

http://www.instructables.com/id/Laser-Flashlight-Hack!!/
step 3: Extract the DVD Laser Diode
After removing all of the screws from the DVD burner, remove the cover and the DVD drawer. This will expose the laser carriage assembly.

step 4: Extract the Laser Diode..

While all DVD burners are a bit different, they all rely on 2 rails that the laser assembly moves on. Remove all screws and do whatever it takes to free up the rails so the
laser assembly slides off. Disconnect or cut and cabling and flat connectors.

Image Notes
1. Laser Assembly

step 5: Continue extraction...

Once you have the assembly off of the burner it's time to start disassembling it by removing all the screws you see. There will be many small screws so be patient. Cut
any flat cabling off. There could be two diodes, one for the CD portion of the burner (IR diode) and the actual DVD burning diode (red). That is the one you want. There
will be a 3-pin circuit board on the red diode that you want to CAREFULLY remove with a soldering iron revealing 3 pins. You can test the diode with 2-AA batteries and
referring to the polarity chart (on the video). You will have to remove the diode from the housing and that will be in a case-by-case basis depending on the burner. The
laser diode is fragile so take care in the final extraction process.

http://www.instructables.com/id/Laser-Flashlight-Hack!!/
 Image Notes
1. Typical laser diode assembly. They are usually all different.

step 6: The new DVD Laser Diode!

Here is what your extracting diode will look like!

You can get the burning LASER DIODE HERE

step 7: Preparing the AixiZ housing...

Remove the label from the AixiZ housing and unscrew the housing leaving a top and bottom portion of the housing. Inside the top housing is the original (5mw) laser
diode that has to be removed. I used the bottom of an X-Acto knife and with a couple of sharp taps, the original diode will come out. It will likely be destroyed doing this
but I have been successful in removing them before but using a very small screwdriver and tapping around the diode until it is freed up.

http://www.instructables.com/id/Laser-Flashlight-Hack!!/
 Image Notes
1. After removing the label, using pliers or vide grips, unscrew the housing.

step 8: Assembling the housing...

I used a little bit of Arctic Silver Thermal grease and slowly installed the new DVD diode in the AixiZ housing. Using a pair of pliers, I SLOWLY squeezed the edges of the
diode down into the housing until it was flush. CAREFUL!

Image Notes
1. The new DVD laser installed in the AixiZ housing.

step 9: Installing it in your MiniMag!

After soldering two leads to the positive and negative diode connectors, it's time to install it in the MiniMag. After disassembling the MiniMag (remove the top, the
reflector, lens and bulb) you will need to enlarge the MiniMag reflector using a reaming tool, round metal file or drill or a combination of all three.

http://www.instructables.com/id/Laser-Flashlight-Hack!!/
step 10: Final Step!!
Be sure to remove the batteries from the MiniMag and after checking polarity, slip your new DVD Laser housing down into the top of the MiniMag where the bulb would
go. Screw the top of the MiniMag on and slip the reflector over the Laser housing. You will not be using the plastic MiniMag lens.

UPDATE: If you intend to use this as more than just a novelty item, a driver circuit is recommended. Here is a basic driver circuit that can be built for this
project which will regulate the voltage going to the diode.

Image Notes
1. Be sure to double check the polarity of the diode before installing and powering
it up! You may have to trim the leads. Also, note the adjustable lens to focus the
beam

step 11: Test it out!!

Reinstall the 2-AA batteries and slowly unscrew the top of the MiniMag, turning on your new Laser Flashlight! Caution!! Laser diodes are dangerous and should never be
pointed at any living thing. Thanks and I hope you enjoyed this Instructable!

http://www.instructables.com/id/Laser-Flashlight-Hack!!/
step 12: FAQ
Here are the answers to common questions about this project. Q. Can I use a CD player/burner or DVD player Diode. A. No. Only a DVD burner diode 16x or faster will
work. Q. Do I need the Aixiz Housing? A. Yes. It serves as a heatsink for the high-power diode and also the focusing element is essential. Q. What happens to the
existing circuit board that is inside the Aixiz housing? A. It is not used for this project. You can keep it for a lower mA diode like a standard red laser pointer diode or just
discard it. Q. What's with the 'pins' you used? A. The 'pins' are snippings from old resistors. You can use any sturdy wire. They are soldered to the diode and then
inserted in the mini-mag plastic fitting that original held the mini-mag lightbulb. Q. Can I use a regular laser pointer from the dollar store as the housing. A. See the
previous Question/Answer Q. Can I use another type of flashlight? A. Not sure. This project is based on the mini-mag. Q. My diode is not burning anything. What did I do
wrong? A. In order for the diode to 'burn' it needs to be focused to a fine point and also the object needs to be black or marked black with a Sharpie. Q. Why can't I see
the beam like I can see in the video? A. I used smoke to make the beam visible. Q. Should I use a driver circuit? A. The basis for this project was to show that you could
use a diode from a DVD burner and put it in a flashlight and make it 'burn'. Ths is a novelty item and not designed for long-term or regular use. If you want to do that, a
driver circuit is highly recommended. For answers to any laser related questions, check with one of the popular forums like www.laserpointerforums.com

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Comments
50 comments Add Comment view all 2177 comments

corsi says: Oct 4, 2009. 3:47 PM REPLY

What class is the laser

Koen92 says: Sep 16, 2009. 10:10 AM REPLY

Will a blue-ray diode also work with this module?

force9000 says: Oct 3, 2009. 7:06 PM REPLY

KipKay has a specific tutorial for a Blu-Ray diode, just search it on youtube or here on Instructables

thefr34k says: Mar 20, 2009. 4:07 PM REPLY

Hi, This looks like a fun little project, I scrapped a DVD-RAM drive in hopes of finding the appropriate laser however I did not find anything resembling your
picture of the Diode. The 2 diodes I found were square with oh say 12 pins?

Anyone else tried this with a DVD-RAM/R drive?

killmore231 says: Sep 29, 2009. 4:47 PM REPLY

Yup, just outta luck really. Depends on what drive you get. You can buy a nice one online for about $10 tho at modwerx.com. The LPC-815. I have it,
works great!

gnolnats says: Apr 11, 2009. 9:31 AM REPLY

Why is it when I power the diode there is no narrow stream of light? This is the third diode that I have tried with same results: wide spray of red light.

kiss my donkey says: May 14, 2009. 3:34 PM REPLY

This is a good thing gnolnats its supposed to do that. you just need to get a lens you should put the diode in the AixiZ Laser Module which as he said
serves as a heatsink and a lens then you will get the narrow stream of light

gnolnats says: May 14, 2009. 7:03 PM REPLY

There was no mention of a lens in the tutorial, that I saw anyway. Where would I get this lens?

Thanks for your reply.

UbuntuNinja says: May 18, 2009. 3:40 PM REPLY

Actually, there was a mention of the lens in the Instructable. Read the comment over the picture of the housing being inserted into the Maglight in
step 10.

gnolnats says: May 23, 2009. 10:37 AM REPLY

OK, I got a new question. The new module came and I hooked it up to the maglite and it burned bright as expected for about 10 seconds and
now it only barely lights up. The same for the dvd led that I removed from the burner, it only barely lights up. I got 2 modules so I hooked the
other one up and it burns bright also, but I didn't leave it connected for very long. Why do they burn so dim, are they being damaged? Also, do
you de-solder the original laser and then solder the dvd laser to the little circuit board or wire it directly to the mag lite ignoring the circuit board
that came with the module?

UbuntuNinja says: May 25, 2009. 6:51 PM REPLY

I am still not totally sure of this, but I think the little circuit board that comes with the module because its purpose seems to be regulating
the current to the laser diode. That would also probably fix your other problem with the dim light. You might need a new DVD diode
though.

gnolnats says: May 27, 2009. 6:47 AM REPLY

OK, so I hooked up the second module that I got without modifying it at all and it works, just like the first one did. I only left this one
connected to the 2xAA batteries (maglight) for about 4 seconds, where I left the first one connected for about 10 and it then went dim
and still is even with new batteries. It's rated for 3.2 volts, so how did putting 3.0 volts on it damage it? Now the first module and the
dvd diode both burn very dim, but the second module burns bright like you would expect. What's going on? I tried new batteries.

So, I should put a new DVD laser on the new PCB in place of the weak laser?(the working one, I assume the first one that burns dim
is damaged somehow?)

If I get all of this done and it burns for 10 seconds I'm going to be pissed.

http://www.instructables.com/id/Laser-Flashlight-Hack!!/
 UbuntuNinja says: May 27, 2009. 2:22 PM REPLY
Did you hook the first DVD diode up to the PCB? You said that the first module and DVD laser are dim now but can you tell me
more about the light? What I am asking is do they produce just a weak dot, or was it somewhat weak but also more of a spray
than a point? Because when I first hooded my unmodified Aizix module up to the AA batteries, it was not very bright, just a broad
stream of light, like you would expect from a regular flashlight. Only once I adjusted the focus lens did it make a point.

gnolnats says: May 27, 2009. 4:03 PM REPLY

I did not hook either of the two dvd lasers so far up to the PCB. Both of them produce a weak wide spray of light, not bright at
all like the module was initially. The 2 PCB's that I just received both burned bright initially. The first one I left connected
(unmodified in any way) to the maglite and it went dim after about 10 seconds and still works but is always dim. The second
unmodified module burned bright for the 4 seconds that I hooked it to the maglite, but I quickly disconnected for fear of frying it
too.

I assume that if I power the dvd laser behind the lens that it will produce a point, but it's so dim that I don't believe it will burn
anything, I mean it's barely on.

UbuntuNinja says: May 27, 2009. 5:13 PM REPLY

I am not sure what your problem is, and I am not really an expert on this sort of thing so at this point you might want to
seek help from someone more knowledgeable, although I would be happy to continue giving you assistance based on
what I know. Are you sure you are connecting the polarities right? Check that both the DVD diode and the PCB are
connected right. For the PCB, I am pretty sure that the lead in the middle of the board is - and the one closer to the edge is
+. For the laser diode you should refer back to the Instructable. No matter what diode you use you still have to adjust the
focusing lens until the beam comes to a point.

killmore231 says: Sep 29, 2009. 4:45 PM REPLY

The diode is dead. There should be a big warning on this saying to use a driver. Check out Laser Pointer Forums for
more info, and find out how to make your own driver so it doesnt die in a VERY short amount of time. Also, you can get
a nice LPC for ~$10 shipped! (250mW)

kiss my donkey says: May 26, 2009. 5:47 PM REPLY

yeah I'm sorry If I wansn't clear UbuntuNinja Is right

UbuntuNinja says: May 26, 2009. 8:57 PM REPLY

I actually have a question about the video you provided. What is the little thing that the guy puts the soldering iron over to de
solder the circuit board? And just to confirm no resistors are needed if I use the circuit board in the end product? If I do need
resistors what value should I use?

nomooremr.niceguy says: Jun 10, 2009. 7:29 PM REPLY

The thing that guy was using is called a desoldering braid. It's a braid of copper wire for, well, desoldering. Like the name says.
It's all very creative, I know. So you place the braid on the solder and the iron on the braid. The solder then melts and bonds to
the braid as opposed to the joint. It comes in handy. I generally use a desoldering bulb, but most of the time the braid would be
more effective. I hope that was helpful.

kiss my donkey says: May 27, 2009. 5:48 PM REPLY

To be honest I was wondering the same thing that thing was?? But you do need to have something in the circuit to limit
current. What I did was use an LED and a 100k ohm potentiometer and I started with 4.5v and it cut down the voltage to
around 2.8 which is fine for me

UbuntuNinja says: May 27, 2009. 7:36 PM REPLY

How does the LED help? How did you wire the potentiometer into the Maglite and how did you start out with 4.5V? Two AA
batteries (what goes in a Maglite) only make 3 volts. To get to that 4.5 volts you would need 1 more AA battery. Is there a
certain value of resistor that I could use that would reduce the maglite's 3V down to the 2.8 you are talking about? Do I
need to have extra resistors even if I use the little circuit board from the back of the Aixiz module?

kiss my donkey says: May 27, 2009. 8:37 PM REPLY

well I didn't even use the Maglite. I made my own circuit and I used an LED so that when ever the laser is on the LED
would light up its just a safety feature. When I wired the potentiometer I wired it to the positive wire. I ran a wire to the
center pin and then out then one next to it, If you do that make sure to use the center pin it doesn't matter what edge
pin you use but you have to the center pin. I am not sure the value of the resistor you would need to make 3v down to
2.8v but It wouldn't be much.

I hope this Helps!

http://www.instructables.com/id/Laser-Flashlight-Hack!!/
 kiss my donkey says: May 25, 2009. 6:43 PM REPLY
You probably fried the diode from to much voltage, but you may have weak batteries. you should just take out the little circuit board and
put the DVD diode in the heatsink with the lens from the module and then hook it all up. This whole Instructable is a bad idea because of
the voltage going to the diode the lifetime will be very short you should at least use a resistor or potentiometer to limit the voltage

kiss my donkey says: May 15, 2009. 7:09 PM REPLY

oops sorry I was thinking of another instructable. To get a good lens go http://www.mfgcn.com/_wsn/page2.html then order the 5MW 3.2VDC
one. when you get it, take of the warning label untwist the top off it and then take out the weak diode and put your powerful diode in close it all
back up. and add power and than your done

UbuntuNinja says: May 27, 2009. 8:03 PM REPLY

Do you know what the specifications for a laser would have to be for the beam to be visible when it is going through the air without using
smoke? Would any of the lasers on that page fit that description?

gnolnats says: May 16, 2009. 8:42 AM REPLY

OK, I ordered that one. Thanks for the tip.

kiss my donkey says: May 16, 2009. 6:41 PM REPLY

great, let me know if you have any questions

kiss my donkey says: May 17, 2009. 4:32 PM REPLY

Hey gnolnats here is a great video I found on how to put the diode in the AixiZ housing
http://www.youtube.com/watch?v=uOhyJ8JyBEo&feature=related

gnolnats says: May 18, 2009. 12:52 PM REPLY

Thank you so much for helping me out with this. I'll let you know how it turns out.

kiss my donkey says: May 18, 2009. 2:01 PM REPLY

Thats great

Thanks!

djr6789 says: Apr 12, 2009. 3:20 PM REPLY

dude are you using a focusing barrel?

gnolnats says: Apr 12, 2009. 8:01 PM REPLY

I guess not. What's that?

ANNM013 says: May 8, 2009. 2:58 AM REPLY

LOL

DannytheGreat says: Sep 28, 2009. 5:27 PM REPLY

could it be used like a laser engraver in any way?

eddiekim95 says: Sep 24, 2009. 5:21 PM REPLY

i dont know why, but i cant open the top part of my minimag. the very top ring wont come off

jimkash says: Jun 12, 2009. 8:10 PM REPLY

i dont knw what for evry1 liked this instructable.. i simply got a pointer laser for less than 1$ whats special to break a burner and do all this y not simply get 1
which is so cheap

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 flakman says: Jun 15, 2009. 4:40 PM REPLY
Your $1 laser will not be strong enough to do anything but burn out someone's retina. The DVD burner diode will produce enough heat to actually cause
some etching in material. I wouldn't break a working burner to do this. There are plenty of bad burners to take apart for this.

dmhjah says: Aug 24, 2009. 9:17 PM REPLY

What could you etch with it?

flakman says: Aug 31, 2009. 12:30 PM REPLY

dmhjah: Not sure about all that can be etched with this. This would be good information from someone that has built one already. Give some
examples of time/burn quality.

laserz1111 says: Sep 21, 2009. 5:44 PM REPLY

You can burn electrical tape, light matches, pop balloons, maybe light homemade black powder, and maybe light cigarettes

ryanforddd says: Sep 20, 2009. 9:28 PM REPLY

I am having the same problem as you George, I still can't figure it out. did you?

King_Chaos says: Sep 16, 2009. 2:23 PM REPLY

Hello! I was wondering if I could use and regular dvd player diode. also if not can u use and old xbox. and could u just buy one. a diode of course.

zatchy21 says: Sep 15, 2009. 5:06 PM REPLY

any ideas on how to make a driver small enough to fit in the minimag case? or at least small enough to fit in your pocket?

aagrios says: Sep 13, 2009. 1:41 PM REPLY

i will pay you for that or the laser lighter

JudgeMonkey says: Aug 15, 2009. 5:32 PM REPLY

After much work, I managed to open the laser housing. Had to use two heavy pliers to do it.

But now that dang laser diode will NOT come out. Since I don't care about the diode, I pushed as hard as I could, and it just won't budge.

I don't have an exacto knife, so I have been using a pen.

Ryo_Ohki2 says: Sep 10, 2009. 9:34 PM REPLY

can you access the diode from the laser side and stick a stick in it and hammer it out? Don't know what housing your using so I can't really suggest
much.

expidition says: Aug 20, 2009. 1:24 AM REPLY

does anyone else have 2 diodes from 1 dvd burner like me?

force9000 says: Sep 10, 2009. 8:22 PM REPLY

The drive your using is most likely a combo drive, the clear-ish diode is for cd's and will not work, the blue-ish one is the burner that you can use.

shinigami17 says: Aug 24, 2009. 6:25 AM REPLY

can i use 52x dvd writer?

Darter76 says: Sep 10, 2009. 7:09 PM REPLY

where would the driver circuit fit in the flash light if u wanted to put one in?

view all 2177 comments

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