Results of an extended series of experimental studies into the beam parameter product (BPP) of high-power diode lasers are summarized, covering efforts to clearly diagnose the limiting factors and develop novel device technology to address these limits. We review diagnostic studies, separating BPP empirically into bias-dependent (thermal) and bias-independent (non-thermal) terms for convenience of analysis. First, we use monolithically grating-stabilized lasers to confirm the presence of a well-defined series of guided modes, rather than filaments. Second, we present results from a series of custom devices and tests (guided by targeted simulations). Third, we show that effects driven by thermal lensing and current spreading dominate the variation in BPP with bias. The residual bias-independent BPP background remains around 30- 50% of the total, and is most likely partly limited by gain-guiding effects. Fourth, the presence of longitudinal temperature variation due to non-uniform optical intensity along the resonator further degrades the bias-independent background level. Lateral current blocking technology is shown to reduce current spreading, and improve the bias-dependent BPP. Thermal engineering also improves bias-dependent BPP, achieved by varying epitaxial layer structure and by targeted changes in bar layout, clarified using measurements in thermography cross-referenced to simulation. In summary, we contend that experimental studies have allowed the effects that limit lateral BPP to be largely clarified, so that research efforts can now focus on developing device technology suitable for reducing BPP without other penalties. The background level to BPP remains an open topic, and further study is needed to better understand and address this.
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