A number of approaches are currently being used to combine the beams from individual diode laser bars to achieve high average power. The limited number of systems available commercially are based on sophisticated water cooled stacks with varying levels of optical complexity. In these systems, the expected cost reduction benefits of diode lasers have not yet been realized, at least in terms of capital costs. In this paper, a fresh holistic approach to high power diode laser design is presented. This employs a novel approach to thermal management as well as incorporating an optical delivery system with a large working distance. Results on the optical characterization of such a design are presented and the techniques by which higher brightness can easily and cost effectively be achieved are explained.

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