Initial DPSS Alignment Using a HeNe Laser
Where positioning of the OC mirror doesn't result in lasing, will be necessary to go back and do alignment 'off-line'. This is best accoplished with a low power HeNe laser (a laser pointer or collimated diode laser module can also be used) reflecting from the relevant surfaces of the HR and OC mirrors back to its output aperture. Although alignment isn't nearly as difficult or critical for this short wide bore laser as for a long narrow bore HeNe laser, the multiple weak reflections from all of the nearly transparent (for visible wavelengths) surfaces can be confusing (since the actual mirror reflections may not appear significantly different at the red HeNe wavelength than uncoated surfaces or AR coated surface at IR wavelengths. If your HR is coated to reflect at 532 nm, a green alignment laser may be better). The trick is to identify the relevant pair!
Where some optics are curved (usually at least the OC), the differences in reflected spot size can be used to identify the which surface it belongs to. To simplify things, the KTP can be removed for initial alignment eliminating two confusing surfaces.
The basic idea is to set up the alignment laser (A-Laser) so its beam shines precisely through the center of the OC and HR (the hole in the plate facing the pump diode. The output aperture of the A-Laser should be defined by an opaque card with a hole in it that is the same size as its beam - typically 0.5 to 1 mm. With a fixed mount for the vanadate, the beam should be reflected directly back into the output aperture of the A-Laser. If it is not, the vanadate is tilted or the OC is off-center or something.

Then, adjust the position in X and Y, and/or the orientation (pan, tilt) of the OC to center the reflection from its inner (cavity facing) surface into the output aperture of the A-Laser. When both the reflections coincide in the A-Laser output aperture, alignment should be good enough for some green lasing.
Christoph's DPSS Laser Alignment Procedure
(From: Christoph Bollig (
laserpower@gmx.net).)
With a power meter, I would suggest the following procedure. You will also need a HeNe laser or laser pointer for alignment. A red laser will produce greater reflections from the AR@532nm and IR optics, but green lasers should also be acceptable.
If you can, get your diode stabilized in temperature. The Sony "Laser diode guide" has useful simple circuits but the following will also work if you just apply a constant current to the TEC and check the temperature every time before a measurement.
Take everything away except for the pump diode and the vanadate.
Measure transmitted pump light behind the vanadate. Since you haven't got a resonator, that's all there will be.
Optimise the diode temperature for maximum absorption.
Rotate the vanadate by 90 degrees.
Optimise the diode temperature again.
At this point, you will know the optimum orientation and optimum temperature. Set it up that way.
Optional (will not give you a lot): Optimise absorption by fine alignment of the vanadate rotation. If the vanadate was cut properly, this isn't necessary but if you just have a random chip, try it.
Shine the alignment laser along the optical axis onto the vanadate. First you have to check whether front and back surface are parallel. If not, you will get two reflections. Align the vanadate so that it will reflect the HeNe or pointer straight back into itself. This is exactly the path the 1,064 nm will take, and almost exactly the path for the green.
Set up the rest of the laser without touching the vanadate or alignment laser.
Align the output coupler so that the reflection of the curved surface (the larger reflected spot) shines straight back into the alignment laser.
With a bit of luck, you should already have a good output. For the fine alignment, touch only the OC and the KTP.
Try the KTP rotated by 90 degrees about the laser axis and align again.
Once you know the best orientation of the KTP, you can start to play with the cavity length. I would change the length and then re-align. Try a few lengths, and take power measurements of all of them (after re-aligning the KTP and vanadate every time). This should give you a "curve" of power versus length, and then you can choose the best.
An alternative starting at step (9) would be to leave out the KTP and tweak alignment for maximum 1,064 nm leakage through the OC. Make sure, you measure 1064 nm only, since the absorption of 808 nm might increase when the laser starts. Then install the KTP and continue with step (12).