Just wondering, if i were to get a 20mw 405nm diode housing with the driver and everything wired, then take it apart and replace the diode with a 100mw 405nm diode, would it still function without seriously cutting the life of the diode?
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The diode will be fine since it is rated for 100mw, while the driver may not be fine. You will need to replace that driver for sure. I build lasers as a hobby myself and for the most part you can overclock a driver by introducing a higher voltage. The current difference is not drastic in the details you provided, so that I would not worry about. The diode I can guarantee will be just fine, if I could make a recommendation as to a new driver. Something I recently bought for my steam-punk laser goggles.
http://www.ebay.com/itm/405nm-Violet-Blu…
I actually went with the 1 watt model but it works well and is a good price. Like I said, the diode will be fine. The drivers life will be cut short. Although if I am reading the additional details correctly, it wont be cut by much. You can probably get away with that actually.
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Im not going to tell you that you don't need safety glasses for this. I mean they are cheap and all but they really inhibit the view of the laser. With my 1W or even 2W lasers I only use the glasses for prolonged use and of course never shine it on a reflective surface. At 100mw though, I wouldn't sweat it. Not a VERY powerful laser but still is kinda dangerous. I mean the glasses are about 2 bucks on ebay, just get them for prolonged use and you really only need them indoors. Even with my 2 watt outdoors it isnt so bad. Indoors, if you stare at it for a while you start to see spots and thats generally a good time to stop or use the glasses but just use common sense and you will be fine.
http://www.ebay.com/itm/405nm-Violet-Blu…
I actually went with the 1 watt model but it works well and is a good price. Like I said, the diode will be fine. The drivers life will be cut short. Although if I am reading the additional details correctly, it wont be cut by much. You can probably get away with that actually.
EDIT-----
Im not going to tell you that you don't need safety glasses for this. I mean they are cheap and all but they really inhibit the view of the laser. With my 1W or even 2W lasers I only use the glasses for prolonged use and of course never shine it on a reflective surface. At 100mw though, I wouldn't sweat it. Not a VERY powerful laser but still is kinda dangerous. I mean the glasses are about 2 bucks on ebay, just get them for prolonged use and you really only need them indoors. Even with my 2 watt outdoors it isnt so bad. Indoors, if you stare at it for a while you start to see spots and thats generally a good time to stop or use the glasses but just use common sense and you will be fine.