Compact optical engine and method of manufacturing same

A laser projector comprising:

• a plurality of laser diodes attached directly or indirectly to a base substrate;
• at least one laser diode driver circuit configured to selectively drive current to the laser diodes;
• a cap comprising at least one wall and at least one optical window, the cap attached to the base substrate, wherein the at least one wall, the at least one optical window, and at least a portion of the base substrate together delimit an interior volume, the plurality of laser diodes are disposed in the interior volume, an interface between the cap and the base substrate provides a hermetic or partially hermetic seal between the interior volume of the cap and a volume exterior to the cap, and the optical window is positioned and oriented to allow light emitted from the laser diodes to exit the interior volume via the optical window;
• a plurality of collimation lenses adjacent the at least one optical window, each of the plurality of collimation lenses positioned and oriented to receive light from a corresponding one of the laser diodes through the at least one optical window;
• a beam combiner configured to combine light beams received via each of the collimation lenses into a single aggregate beam;
• and
• at least one scan mirror disposed to receive laser light from the plurality of laser diodes, the at least one scan mirror controllably orientable to redirect the laser light over a range of angles.

A wearable heads-up display (WHUD) comprising:

• a support structure dimensioned to be worn on the head of a user;
• and
• a laser projector attached to the support structure, the laser projector comprising:
• a plurality of laser diodes attached directly or indirectly to a base substrate;
• at least one laser diode driver circuit configured to selectively drive current to the laser diodes;
• a cap comprising at least one wall and at least one optical window, the cap attached to the base substrate, wherein the at least one wall, the at least one optical window, and at least a portion of the base substrate together delimit an interior volume, the plurality of laser diodes are disposed in the interior volume, an interface between the cap and the base substrate provides a hermetic or partially hermetic seal between the interior volume of the cap and a volume exterior to the cap, and the optical window is positioned and oriented to allow light emitted from the laser diodes to exit the interior volume via the optical window;
• and
• a plurality of collimation lenses adjacent the at least one optical window, each of the plurality of collimation lenses positioned and oriented to receive light from a corresponding one of the laser diodes through the at least one optical window.