We have previously presented a very low size, weight and power (SWaP) rugged coherent beam combiner assembly designed for LDEW systems. This module used our monolithic, freeform array optics to create a collimated, shaped and tiled array that allowed for greatly increased power-in-bucket (PiB) compared to traditional gaussian beam systems. We now present a design solution increasing the channel count from 7 to 61, with detailed modelling of the return loss and thermal effects when the entire module is subject to a total input optical power of 183kW. Furthermore, we propose the design of a high-power endcap fiber array to support the complete assembly which will allow for >3kW power level per channel.
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