So this weekend I was procrastinating from stuff that really needed to get done, so I decided to replace my old star projector that fills my great room ceiling with green 'stars'. The 532nm diode that is the heart of that thing was dying after running ~6 hours a day for 13 years. I dissected the optics from the thing to find two overlapping glass gratings that made a nice 'starfield' breakup which was then furthered by another plastic scan-through grating that rotated to make a waaaay to busy 'sky'.
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The replacement I had in mind was centered on a couple things that I had handy. A couple 488nm single mode diodes and a cool little sample grating thingy that my friend Ed (ekeefe) gave me a couple years back. The idea was us use parts that I had sitting around that I'd never use in a regular projector build including old diode mounts, large bounce mirrors and a 3x diode driver that didn't even have Bias pots (!).
This little sample grating has a really nice rotating Earth, a rotating moon, a constellation that draws the line between the key stars in one area and without it in another and finally a static detailed image of another section of the night sky. The last two were what I wanted to incorporate into the replacement star projector, but unfortunately even with 22 feet of throw from floor to ceiling, the throw ratios on those gratings only cover about 1/6 of the ceiling each. Rather than deal with telescoping them, I decided that they should be 488nm 'feature areas' and I'd just fill in the rest of the sky with 450nm using the gratings I salvaged from the old star projector.
Since the constellations were feature areas, I bounced them on separate mirrors, one paired with the grating 450nm stars. In the end, I've got a much improved two color sky that looks much better than any of these silly laser based toys we see for sale. It's definitely not a proper star projector like SpitzSTP collects, but for $0 and a footprint of 6"x4"x2", I'm pretty happy with the results. Oh, and before anyone asks, yes the zero order beam is 5mw even with the brightness pot turned up all the way.Here's a few more pics. The brightly lit room and short throw doesn't do the star fields justice so I'll try to take some pictures of it in the great room tonight after the sun goes down.
-David