DILAS (Mainz, Germany) now delivers 40W output power from a T-bar based 638nm 400-micron/0.22NA, fiber-coupled module used for cinema projection. Through the optimization of semiconductor chip structures and optical parameters, DILAS’ tailored bar (T-Bar) architecture delivers high beam quality and high power using standard micro-optic fast-axis collimators (FAC) and slow-axis collimators (SAC), all assembled with automated processes. The T-Bar is a monolithic multi-emitter source, allowing the handling of multiple emitters during each manufacturing step, to lower complexity and ease manufacturing. The result is enhanced reproducibility, beam quality and fiber coupling efficiency. Extending the T-Bar based scalable concept, more advanced modules will soon be made available to enable development and commercialization of high power diode laser based RGB projection laser systems.