Abstract: A mounting improvement for the solid state laser bars used for example to pump high power lasers is provided. Solid state laser bars are mounted in side by side relationship and combined with integrated substrate and laser output directing optical elements on a disclosed Integrated Diamond Carrier. The Integrated Diamond Carrier is preferably fabricated as an essentially freestanding base plate of diamond composition with incorporated arrays of mesa structures providing mounting for the laser bars and providing integral laser output directing optical elements such as mirrored prisms. Integrated diamond carriers according to the invention provide stable positioning, desirable thermal conductivity and consistent low temperature operation for the solid state lasers.

Abstract: A method of making efficient Integrated Diamond Carrier heat sink and mounting structures usable typically to mount the solid-state laser bars often employed for pumping high power lasers, for example. The disclosed method forms the Integrated Diamond Carrier on a shaped sacrificial substrate member by chemical vapor deposition growing of diamond on a patterned substrate, made from for example silicon semiconductor. The substrate serves as a mold and is etched away after Integrated Diamond Carrier base plate formation leaving the freestanding diamond carrier. Optically usable surfaces are achieved on the Integrated Diamond Carrier through use of substrate crystal plane characteristics and an improved deposition arrangement.