Array of diffraction limited lasers and method of aligning same

A two-dimensional semiconductor laser array assembly, comprising:

• a) a plurality of one-dimensional semiconductor laser array assemblies wherein each one-dimensional semiconductor laser array assembly comprises:
• 1) a one-dimensional semiconductor laser array having a plurality of emitters wherein each emitter is electrically connected to a power supply means;
• 2) a heatsink means for absorbing heat from the semiconductor laser array;
• 3) a bonding means for attaching the semiconductor laser array to the heatsink means and transferring heat from the semiconductor laser array to the heatsink means, the bonding means having a uniform thickness;
• 4) a refractive lens means for collimating a fast axis of the output of each emitter of the semiconductor laser array;
• and
• 5) a one-dimensional array of binary optical elements for collimating a slow axis of the output of the emitters of the semiconductor laser array and correcting aberrations therein, wherein each individual binary optical element corresponds to a distinct individual emitter of the semiconductor laser array, each binary optical element comprising a substantially planar substrate having a front surface wherein the front surface has been formed such that the optical path length travelled by each ray of divergent light emitted by an emitter of the semiconductor laser array is equal upon the ray's exit from the front surface of the binary optical element;
• and
• b) a clamping fixture for fixedly retaining the plurality of one-dimensional semiconductor laser array assemblies such the plurality of one-dimensional semiconductor laser array assemblies are substantially parallel.

A method for aligning the output of a two-dimensional semiconductor laser array assembly, comprising the steps of:

• a) placing a first one-dimensional semiconductor laser array assembly in a clamping fixture;
• b) placing a second one-dimensional semiconductor laser array assembly in the clamping fixture such the second one-dimensional semiconductor laser array assembly is substantially parallel to the first one-dimensional semiconductor laser array assembly;
• c) positioning a set of collimating optics for the second one-dimensional semiconductor laser array assembly such that the output of the second semiconductor laser array, placed within the clamping fixture, travels through substantially the center of the collimating optics;
• d) supplying power to each of the one-dimensional semiconductor laser array assemblies following the positioning of the collimating optics;
• e) introducing a transform lens in the optical path of the output of each one-dimensional semiconductor laser array assembly to simulate a far field of the two-dimensional semiconductor laser array assembly;
• f) monitoring the power level at the focal point of the transform lens;
• g) altering the position of the collimating optics until a maximum power level is detected by the monitor;
• h) retaining the collimating optics in the position corresponding to the highest power level detected;
• and
• i) repeating steps (b) through (h) for each additional one-dimensional semiconductor laser array assembly of the two-dimensional semiconductor laser array assembly.