What is a diode laser?

July 5, 2022

The core component of a diode laser is a semiconductor diode. More specifically, this is a p-n junction diode made of one p-type and one n-type semiconductor. The p-n junction acts like a turnstile, allowing electrons to flow through the barrier.

Laser diodes typically use semiconductors made of aluminum or gallium arsenide alloys. Current is supplied through the diode, inducing electrons to flow through the p-n junction. These electrons combine with holes on the other side of the junction, releasing excess energy in the form of photons.

The gap between the two semiconductors acts as a "mirror" that amplifies the intensity of the photons. Photons bounce back and forth across this gap and collide with other incoming electronics. This "resonance" helps generate more photons. Hundreds of collisions are required to achieve the desired optical gain in diode lasers.

In more complex applications, multiple semiconductor diodes can be stacked together. Multiple beams from these diodes can be focused into a single beam, resulting in greatly increased output power. This also makes it possible to create multiple lasers with different wavelength values.

Diode Lasers - Pros and Cons
To demonstrate how simple diode lasers are, the typical lasers used in standard laser pointers are low energy diode lasers. That should already tell you how different diode lasers are - they are cheaper, smaller, and can be powered by a small battery.

PROS:
1. Less expensive
Today, you can buy a standalone diode laser kit for less than $200. By comparison, CO2 laser engraving kits cost at least closer to $500. This has made diode lasers very popular among the hobbyist community, even for those who want to start a small business.

2. Compact, lightweight, and robust
Diode lasers are very small and lightweight, making them ideal for DIY projects. They are commonly found in 3-in-1 machines that combine a laser engraver with a 3D printer and CNC machine.

Portable laser engraving machines are also slowly gaining popularity, and they are all based on diode laser technology. It also helps that the diode laser is very robust - regular movement of the diode laser is not a problem, as its semiconductors don't need to be perfectly aligned to work.

CONS:
1. Not as powerful
The biggest trade-off with using a diode laser is that it's very low power. The maximum output of a single diode is 10W. While stacked diodes are possible, laser engraving is not common.

Cutting paper or balsa or engraving on leather is not a problem, but using metal or thicker wood may not be practical. If you're working with more challenging materials, expect multiple passes and longer times with the CO2 laser.

2. Limited applications
Using a diode laser means simply accepting that you cannot engrave or cut many materials. Diode lasers don't have enough power to engrave metal or glass unless some coating has been applied to it. Diode lasers also have difficulty processing any surface that is glossy, clear, translucent, or painted all-white.

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Laser engraving is a popular option that provides a permanent and legible marking on an object through etching, ablation, or deep laser engraving. It is similar to laser marking, but the resulting appearance differs due to the depth of laser penetration.
Laser engraving is commonly used to create permanent serial markings on substrates made of: Metal, Wood, Plastic, Leather.
Benefits Of Laser Engraving Over Traditional Processes
Compared to manual engraving:
Minimally Invasive: Laser engraving can be performed at a range of depths without any direct contact at all. Surface marks can even be done on stainless steel with no depth. Overall, lasers are less damaging than manual engraving and keep the substrate material’s physical integrity intact.
Precise: Lasers provide a level of control that’s impossible to achieve manually. Compared to hand-engraving, the process is swift, clean, and highly repeatable, with little room for human error.
Versatile: A single laser engraving machine can be used to create a host of different designs with only minimal calibration. They can also produce exceptionally complex patterns. Affordable: On average, laser devices last longer than other engraving machines and require less maintenance, resulting in savings that can be passed along to the consumer.
Fast: Lasers can be programmed to render virtually any design in a matter of moments. Because the process is automated, it’s easy to scale production runs as needed according to demand.
Long-Lasting: Laser-engraved designs are permanent but can wear over time, depending on the substrate material that’s used. Soft metals, for example, may experience more signs of wear than hardwood. In general, however, laser-engraved designs tend to have a longer lifespan compared to other engraving methods.