Picture of 1W Altoids Tin Laser!
Just Imagine- The power of a 1w laser, but in the pocket sized package of an Altoids tin! It's amazingly bright- perfect for star pointing. 

We'll start with the parts list:
~Altoids tin
~1-2w 445nm laser diode (Ebay)
~12x30mm Aixiz laser module (Ebay)
~Aixiz three element glass lens (Ebay)
~Slide switch and momentary switch (Radioshack)
~2xAA battery holder (Radioshack)
~7805 regulator (5v regulator). Use a 1A version for about 1W of laser light or a 1.5A one for about 1.5W. NOTE: Using 1.5A regulator will shorten your diodes life compared to the 1A variety. 
~2x 14500 3.7v lithium batteries and charger (Ebay)
Wire, stranded wire around 26 AWG will work best
~A soldering iron and solder
~Laser safety goggles (Ebay). ***These are ABSOLUTELY needed!!!***

Laser module and electrical:
To start, press your 445nm diode into the Aixiz module using the back half of the module and a vice. Once you have completed that, solder your wires onto the diode (I have provided an image showing pin configuration of 445nm diodes, you'll only use two of the pins). ONLY solder onto the diode when it is in the Aixiz module or a heat sink of some sort! Next, screw the back of the Aixiz module back on, and then replace the the standard acrylic lens of the Aixiz module with the three element glass lens. Now that your Aixiz module is ready to go, you will now solder together the rest of the circuit using the schematic I provided in the pictures as a guide, however it does not need to be exactly the same (the safety switch is optional, for example. I just find it nice to prevent any mishaps when I carry it in my pockets). 

The Altoids Tin:
Now that we have completed the electrical side of the build, we can focus on the tin. First, locate and then drill out the locations where you wish to have your buttons/switches and the laser module to be. This part is purely your choice. If you do not have a 12mm metric bit for the Aixiz module hole, a 1/2 inch drill bit should suffice (it ends up being 12.7mm).

Now for the final part of the build: putting it all together! (Its pretty self explanatory) 

An optional, yet recommended extra step:
Without a heat sink, the Aixiz module and 7805 regulator will heat up fast and you risk damaging your diode. So, I HIGHLY suggest that you make/ buy a heat sink for your laser. I built my heat sink out of two small square of 3/8 aluminum plate screwed together with a 12mm hole drilled down the middle of it.

***When operating ANY high powered laser, you MUST always wear laser safety goggles, and they should be at least OD 3***

~Star pointing (Be careful though)
~Demonstrations like popping balloons and starting matches
~Engraving things
~Burning things
~Light sabre fights?! (Jk... I would not suggest doing this)

A note on using it: Adjusting the lens will cause the focus of the beam to change. Focusing it to a point is great for burning, and into a beam is great for distance pointing.

tornadodead made it!2 months ago

Love the tutorial, but I'm experiencing some technical difficulties. I've got the same electrical setup, but my laser is only outputting a very dim blue dot and not the 900mw beam that it should be producing. Any ideas on why it isn't working properly?

afernandez3110 months ago
Would it make any difference if i used a 9v battery because im still gonna use the 7805 voltage regulator anyways, so would it make a difference? Im just wondering because it would fit better in the altoids box?
Revanchist1 year ago
do you mean 2x 4500 mA battery? because 14500 ma battery seems wow
sammydogjj1 year ago
Do you mean a 1-2w diode or a 1 or 2 laser diode?
krausnick1 year ago
This is the most amazing thing I've ever seen. Well done!
sammydogjj1 year ago
Does* last*
sammydogjj1 year ago
Disregard that I see the regulator but how long dies the 1w model lasy
sammydogjj1 year ago
Also why wasn't a driver in the build?
sammydogjj1 year ago
Does any diode fit into the specific module or could I just buy a 1w diode inside a glass lens module
High power laser light. Please tell me where you but it and also about its cost. 
Laser Safety Glasses
Kzummo1 year ago
Wicked lasers? Ain't nobody got money for dat!
BJAKidwell2 years ago
How much would this cost?
Also, I'm doing an experiment involving popping a balloon with a laser so would this be powerful enough?
ApertureScience (author)  BJAKidwell2 years ago
It should cost around $70 (most of the cost being the diode):
$45 for the diode (a M140 from DTRLPF)
$6 for the laser module with lens 
$3 for the Altoids tin 
$5 for the switches and battery holder
$5 for the batteries if you chose to use lithium ones
$5 for the heat sink
$1 for the 7805 regulator
TOTAL: $70

And this laser is definitely powerful enough to pop a balloon.
jwwilson232 years ago
Hey i dont know if you still check up on this instructable but i have a few questions... 
1. is there any materials besides aluminum to make a heatsink(just curious) and do you know where i could buy a nice one that would work well and fit well(not too expensive)
2.i have 4 Ni-Cd AA batterys that are in a series would these work fine or are they worse then Ni-Mh. (i can tell you voltage and mah if you need to know if they will work.)
3.since you have made one of these yourself :) is there a cycle you use too keep it from overheating and diode being damaged.. like maybe 30sec on 30sec cooldown (i have no clue)
4. last one(you probably hate me!) what material would i be able to engrave?

ApertureScience (author)  jwwilson232 years ago
1- Usually your best choices for heat sink materials are aluminum (which has very high specific heat) and copper (which is very thermally conductive). Usually aluminum is the most popular material for heat sinks.
2- The NiCd batteries should work, however I would say that the NiMh batteries are probably be better than NiCd for this purpose due to NiMh cell's considerably higher capacity to size compared to NiCd cells.
3. I try to operate my laser in relatively short bursts, usually the longest being 30 seconds, and allowing it to cool for a good 30+ seconds because I don't want to risk damaging my diode. A big factor dealing with duty cycle is how large your heat sink is and how well it dissipates heat, and for me mine is relatively small and doesn't expel much heat into the environment so my run time and duty cycle suffer. My suggestion is to use as large of a heat sink as you can that is exposed, which should give you relatively long run times, possibly a few minutes on with maybe 30 seconds off.
4- You can engrave just about anything that is not metal or glass/ceramic. Wood, most plastic and even white paper works.
zapskate3 years ago
i might vote for you if you answer this satisfactorily - how long will this expensive (sorta) diode lase in this circuit - meaning without any laser driver?

cuz i would hate to spend $40 bucks on the diode n have it burn out in two weeks of off and on use.

is this as strong ans the blue Arctic Laser rated at 1W? because it seems much cheaper but not as sturdy or with as many accessories or features but if you just wanted the pure laser power without the perks this looks perfect - plus the pleasure of building your own case for it - also it is unclear if you use two AAA batteries to power it or one 3.7v Li-on battery or two so if you could explain that to me, thank you very much in advance! ^_^ otherwise it looks like a great instructable
jdorne zapskate2 years ago
You can get an M140 diode from DTRLPF (google) for $50. That is >3 times as powerful as the arctic. (arctic is actually far below 1W). You wont get much power in an altoids box though because it will overheat.
Danilax312 years ago
I finished my laser!! Your tutorial helped so much, thank you for that. When I point my laser, it seems to be out of focus or different than yours because the beam is rectangular. Can I focus it to be a harsher point? How would I do that? Thanks!
larende2 years ago
can i use with these parts a laser diode from a pc dvd burner
ApertureScience (author)  larende2 years ago
You would need to change the voltage regulator in this design in order to use a DVD burner diode. I believe most DVD burner diodes run off of around 3v and 200-250mA, so all you'd have to do is find a voltage regulator suitable for that range and swap it out for the 7805 in the schematic. On a side note, if you where to use this design for a DVD burner diode, you could probably get by with just one lithium cell due to the voltage needed being lower.
Danilax312 years ago
Where can you buy the Aixiz three piece glass optic? I cannot find one on ebay!
ApertureScience (author)  Danilax312 years ago
Try searching "Aixiz glass lens" on ebay instead, you should see "Aixiz Three Element Glass Lens" come up as an option.

The "Aixiz three piece glass optic" name I used before to describe the lens was actually incorrect, so I changed it to the correct name to prevent any further confusion. Thanks for the comment- it helped!
Sorry to keep bugging you. This is hopefully my final question, while finding a diode I came across this:

445nm M140 Diode In Module With Leads
& Three Element Glass Lens

Would you recommend using this?
ApertureScience (author)  Danilax312 years ago
Not a problem! Anyways, my friend got one of those before and it was perfectly fine, so I would recommend it. They are also nice because you don't have to risk damaging your diode through soldering wires to it yourself.
Awesome thank you so much, and one last question, you said to use a AAA battery holder. Are the 14500 3.7v lithium batteries the size of a AAA? Or a AA?
ApertureScience (author)  Danilax312 years ago
Oops, it should be a AA battery holder. I should have checked over this ins'tible a little more carefully...
philmcm2 years ago
Check out this week's episode of Bones. The bad guy uses a homemade device very very similar to this, including the mint tin, to blind a security camera.
ostomesto3 years ago
This is awesome, one of the coolest things I have seen made from an altoids tin great job!
mm38143 years ago
how much did this cost
ApertureScience (author)  mm38143 years ago
About 60 dollars. Most of the cost of the project was attributed to the 445nm laser diode which are around $40.
axeman9113 years ago
Vanila3 years ago
I hope you have glasses for that laser. Pointing a laser near your face like that is rather risky!
Absolutely, I would recommend your instructable not simply recommend safety glasses, but require them. Blindness is serious business. On a side note...

Cool instructable!!!
ApertureScience (author)  Aleator7773 years ago
Great suggestion! I edited my instructable emphasizing the need for laser safety goggles more, and your right, Blindness is very serious!

ApertureScience (author)  Vanila3 years ago
I most definitely do! I REALLY think it would be foolish not too...

Thanks for your concern!