Consistency and repeatability are difficult tasks in diode laser manufacturing, but they are critical for high-volume manufacturing of devices that users can trust to work as promised. Process repeatability, still the nemesis of most semiconductor laser manufacturers, plays a more critical role in commercial success than does achieving record performance parameters.We have found solid-state molecular beam epitaxy to be a very reliable and reproducible technique for high-power laser diode manufacturing applications. Initial data on high-optical-density operation screening of uncoated devices demonstrate better than 50 percent power efficiency maintained over a wide range of driving currents, peak power efficiency of more than 55 percent and slope efficiency as high as 1.33 W/A…