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XTool D1 Pro 40W review: Is it Best for the performance?

The xtool d1 pro 40w laser engraver from XTool is making waves as a powerful, easy to use, and adaptable diode laser system. With 40W of power, this diode laser promises cutting and engraving speeds rivaling smaller CO2 lasers. But does the xtool d1 pro 40w live up to the hype? To discover out, we test it on a Variety of Materials & Applications.

Overview and Unboxing: Well Packaged and Quick to Assemble

XTool D1 Pro 40W review: Is it Best for the performance?

Ordering the xtool d1 pro 40w gets you both a 10W laser for precise engraving and the 40W high power diode laser in the kit. Unboxing reveals two neatly packed boxes, one containing the 40W laser module and X gantry and the other with the full engraver frame and accessory components. 

Everything in the boxes is logically packed with color coded screws to make the assembly process smooth. With clear instructions, we were able to fully assemble the xtool d1 pro 40w in under an hour with no issues. XTool provides all necessary tools and components, leaving nothing to chance.

XTool D1 Pro 40W review: Is it Best for the performance?

The physical build quality of the xtool d1 pro 40w seems excellent. Sturdy metal framing should provide stability during high speed operation. The 40W laser module impresses with well designed mounting points and branding that fits perfectly into place. Everything about it is well-made, from the structure to the packaging, with obvious attention to detail.

Key Features and Specifications

As a diode laser engraver, the xtool d1 pro 40w stands out through its balance of power, size, speed, and ease of use. The following core features allow it to function as it does::

XTool D1 Pro 40W review: Is it Best for the performance?
  • Power Output – 40W diode laser module provides high power output for faster cutting and engraving
  • Work Area – 430 x 348 mm work area (16.93 x 13.7 inches) can accommodate large projects
  • Expandable Work Area – Upgrade kit expands engraving capacity up to 909 x 430 mm (35.79 x 16.93 inches)  
  • Cutting Thickness – Can cut up to 18 mm hardwood, 15 mm acrylic, and 0.1 mm stainless steel
  • Engraving Speed – Up to 400 mm/s engraving speed rivaling small CO2 lasers
  • Connectivity – USB, WiFi, and micro SD card connectivity for wireless or wired operation
  • Compatible Software – Works with XTool Creative Space and LightBurn software 

With 40W of power in a diode laser, robust connectivity options, and high speeds, the xtool d1 pro 40w looks great on paper. But specifications don’t reveal real world performance – for that we move onto testing.

Real World Cutting and Engraving Performance

We assessed the engraving and cutting ability of the xtool d1 pro 40w across a range of natural and synthetic materials. For all testing, we enabled air assist and used a metal honeycomb bed for cutting. Engraving remained precise and clean without air assist on materials like wood.

XTool D1 Pro 40W review: Is it Best for the performance?

Engraving Performance on Natural Materials

The 40W diode laser inside the xtool d1 pro 40w made short work of commonly engraved materials like wood, bamboo, leather, and fruit. It proved to be Faultless at managing Intricate tasks.

On bass and cherry wood, we engraved text and graphic elements at over 170 mm/s. Fine details like small text and thin lines rendered perfectly even at high feed rates. For these organic materials, there was no discernible advantage over a well tuned smaller wattage diode laser. Engraving depth reached over 1 mm on both woods with minimal charring or burning.

Cork, leather, and coconut had similarly impressive results. On all three materials, we achieved clean, consistent 1 mm depth engraving without any unexpected combustion issues even at speeds over 200 mm/s. For fruit engraving, we did have to drop speeds to around 50 mm/s to cleanly vaporize the outer layer without causing deeper burning.

Based on engraving ability alone on organic materials, even lower cost diode lasers can achieve professional looking results. The xtool d1 pro 40w differentiates more during cutting and on synthetics.

Cutting Performance: From Wood to Acrylic

It is during cutting that the 40W power output of the xtool d1 pro 40w shows its advantage. We compare speed and cut quality by cutting a variety of Woods, acrylics & other materials.

XTool D1 Pro 40W review: Is it Best for the performance?

On plywood, layered woods, and hardwoods like oak and maple, the results impressed. At a 10 mm/s feed rate, the xtool d1 pro 40w carved through 10 mm plywood in a single pass. On maple, it managed over 10 mm depth while on oak it exceeded 12 mm cutting depth. When cutting wood over 5 mm thick, multiple slow passes generally produced better edge quality.

Engraving leather produced clean consistent cuts at 5+ mm depth even at speeds over 100 mm/s. Only thin leather under 2 mm experienced charring at high feeds rates – an easy fix by slowing down.

Acrylic cutting highlighted the precision possible. We cut 1-5 mm black, red, and white acrylic cleanly without any heat damage beside the cut line. As expected, the 40W diode laser could not engrave or cut transparent or translucent acrylic. Sections with intricate cutout patterns and small holes showed impressive accuracy.

For metal, the 40W laser etched stainless steel cleanly despite the focus on power over precision. The cuts measured under 0.15 mm but smoothly removed the top coating. Processing coated metals and anodized aluminum worked similarly well for doing custom etchings.

Across this diverse set of cut tests, we found the xtool d1 pro 40w outperformed expectations for a diode laser. The power upgrade over smaller devices directly translated into much faster and deeper cutting while maintaining high precision.

Ease of Use and Reliability

Beyond raw performance, the xtool d1 pro 40w impresses with well designed accessories, software compatibility, and reliability. These factors make the transition from idea to finished product almost seamless.

XTool D1 Pro 40W review: Is it Best for the performance?

XTool built the laser cutter’s bed to easily integrate upgrades like air assist and honeycomb beds. We found adding air assist essential for cutting projects to direct ventilation right at the point of power application. The honeycomb bed also becomes necessary during cutting by providing a safe space for waste material and ventilation to prevent backing up into the laser path.

The integrated air tube connector immediately worked with standard 4 mm air tubing. After installing a small air pump, the direct air assist produced noticeably cleaner cuts by blowing away material before combustion kicked in. We did have to manually hold the tubing in place until getting securing clips – the only minor inconvenience we experienced.

For software, the bundled XTool Creative Space software unpredictable performance but delivered usable functionality. We preferred running the xtool d1 pro 40w in LightBurn after initial configuration. LightBurn played perfectly with the engraver and made it simple to translate designs into production ready layouts. Connectivity via USB, wireless, and Micro SD card afforded plenty of flexible options.

Over dozens of hours of testing, we encountered no mechanical Issues or loss of power. Alignment remained precise even after repeated projects. The modular design means replacing components like the lens takes under a minute by just swapping in an identical replacement. By following instructions setting up the xtool d1 pro 40w and implementing safety tools like air assist and ventilation, we found no exposure issues either thanks to the Class 1 laser.

Between well integrated accessories, reliable construction, and flexible software options, ease of use clearly received focus during the design process. Someone with basic technical experience can have the xtool d1 pro 40w fully running in under an hour from unboxing to cutting.

Compatible Accessories to Enhance Capability

A major advantage of the xtool d1 pro 40w comes through compatibility with affordable value adding accessories. We tested the engraver with XTool’s options for air filtration, noise reduction, rotary attachments, and physical size expansion to see how well they work together.

XTool D1 Pro 40W review: Is it Best for the performance?

The onboard air assist plus an air pump provided noticeable improvments to cut quality on synthetics and engraving cleanup on wood. Further air management becomes important when operating without sufficient workshop ventilation. For managing indoor air quality, we paired the accessory HEPA filter (9) with a dryer vent exhaust hose. Together they removed the faint burning smells from leather and wood engraving. If noise matters, add on the muffler () which significantly cuts down on fan and motor sounds.

Expanding beyond flat items, we set up XTool’s RA2 Pro rotary attachment (9) for engraving glasses, mugs, and cylinders. The RA2 pro adjusts to fit a huge range of diameters (60-180 mm) and syncs directly with the laser cutter. After some test runs dialing in positioning, we produced professional quality etchings on steel and glassware at surprising speed. If ring and bracelet engraving appeals, a small flat rail addition handles those as well.

For workspace flexibility, the impressive Expand module (9) more than doubles work area up to 900 x 430 mm. We found it to integrate directly and maintain alignment accuracy even at that scale.

Commercial customers concentrating on bulk processing tasks where eliminating layout batching becomes beneficial could find the extend kit appealing.

Even large 100+ mm tall pieces fit when using higher base risers ( for 45 mm options).


Altogether the first party accessory ecosystem around the xtool d1 pro 40w provides practical upgrades at reasonable prices. Between air assist, rotary capability, filtration systems, and expand modules, customizing the engraver to specific use cases works seamlessly.

Direct Comparison to a 40W CO2 Laser

The 40 watt diode laser packed into the xtool d1 pro 40w promises power rivaling entry level CO2 lasers. Does such assertion, nevertheless, yield outcomes in the actual world? To answer the question, we directly compared performance across several tests against a heavily upgraded commercial K40 CO2 laser cutter (12 x 8 inch bed).

XTool D1 Pro 40W review: Is it Best for the performance?

Our CO2 test unit operated with air assist for cutting and an LED lightstrip for easy material positioning – both minor upgrades. Even with over 2 years of tweaks, tuning the K40 requires vigilence to maintain power & precision as the mirrors start to naturally misalign. The open frame CO2 also needs manual fume extraction through filters and venting to prevent buildup.

In contrast, the contained diode laser on the xtool d1 pro 40w requires no servicing except for infrequent lens cleaning and modular component swap outs. While providing equivalent cutting ability, the overall experience favors less fuss with optics.

We engraves basswood planks with similar geometric patterns at both machine’s full settings. At 70 mm/s feed rates, the CO2 produced slightly deeper engraving but also more pronounced wood burning on the edges. Cleaning up engraving char marks took a few minutes per piece. On leather, cardboard, and painted metal, both lasers delivered essentially equal quality etching around 0.5 to 1 mm deep.

For cutting thin plywood below 5 mm, either laser similarly sliced through the sheets in a single pass. On 10 mm plywood, the diodes slower feed rate produced markedly cleaner cuts barely needing any trimming. Through 12 mm cuts, only the CO2 succeeded but also left rougher edges requiring more secondary clean up.

Acrylic cutting highlighted an area where scrap remains problematic with CO2 regardless of tuning. Burn marks stretched 3-5 mm from the cut lines and required manual removal. The diode laser etched then cut the acrylic far more precisely with barely any heat damage beside the narrow cut line itself.

As expected, the CO2 laser had no issue with transparent acrylic while failing there risked internal diode laser damage. Trade workers depending on clear acrylic compatibility would still want a CO2 model. However, the xtool d1 pro 40w actually seems safer overall for home use when consider fumes and heat.

For those engraving and cutting as hobbyists or starting a small business, the plug and play xtool d1 pro 40w matches up well against entry level CO2 lasers. The diode modeloffers tighter process control through software, built-in air assist and honeycomb options, and reduced maintenance needs. Unless clear acrylic or specialized application depends on pure CO2 wavelength, we found the xtool d1 pro 40w an easier experience at comparable hobbyist speeds for under 00.

Does the investment make sense? Concluding Thoughts

Outstanding performance for a midrange home and small business laser is provided by the XTool D1 Pro 40W engraver. Combining 40 watts of diode laser power with robust accessory support and reliability makes it stand out compared to both budget diode and entry level CO2 options. Thanks to intuitive operation combined and requiring only minor safety considerations, the investment pays dividends through production ready operation the first time you power on.

XTool D1 Pro 40W review: Is it Best for the performance?

If buying purely as hobby engraver, less expensive and much smaller diode lasers provide almost equivalent results. Stepping up to the xtool d1 pro 40w only makes sense if you specifically need optimized cutting performance or larger size compatibility. In that case, the hundreds extra dollars directly contribute to productivity.


For anyone seeking to sell engraved, marked, and carved goods as a solo creator or startup business, the xtool d1 pro 40w warrants serious consideration. We found it fully capable of executing repeatable production jobs across dozens of realistic small scale product options from wood decor to etched tumblers and pet ID tags. Support for ancillary tools like rotary attachments further expands possibilities into customized drinkware and jewelry.

Given the robust metal construction, largely hassle free operation, and plug-and-play design, the XTool D1 Pro 40W laser stands out as flexibly suited to anything from home crafts to full time business supply. While not inexpensive upfront, if you have decided to pursue laser cutting and engraving work professionally, we think buyers with cash in hand would be pleased with performance over time versus the monthly cost of leasing commercial systems. Outright purchasing means no restrictive monthly payment schedules and the freedom to fully customize the work environment around the reliable xtool d1 pro 40w.

Ideal Honeycomb Composition

For best cut quality and safety, XTool sells stainless steel, aluminum, and silicone honeycomb beds matching the laser cutter’s dimensions. We found the stainless steel honeycomb ideal on the 40W system given its rigidity and ability to handle the heat levels involved.

Importance of Safety Protocols

Operating a 40W laser requires paying close attention to engraver safety no matter how easy the physical operation. Be sure to constantly monitor your projects and implement the necessary ventilation, filtration, enclosures, and fire prevention tools before starting.

Also read:
What is xTool laser? Is xTool better than Glowforge in 2023?
xTool P2 CO2 Laser Cutter vs Jpt 50w Fiber Laser Find Best ?
Is xTool S1 the Best Tumbler Laser Engraver Machine in 2023?
xTool P2 vs Omtech Polar: Comparing Two Popular Laser Engravers

Protective Storage and Shipping

Consider adding on a dust-proof cover () or high density plastic enclosure (9) to protect the xtool d1 pro 40w from dirt and dampness during storage or shipping.

Safety Through Beam Containment

Unlike exposed CO2 systems, the xtool d1 pro 40w beam stays neatly contained only emitting from a pinpoint opening to enhance safety.

Business Flexibility

For startup businesses wary of being locked into long monthly payment cycles, outright purchasing the capable xtool d1 pro 40w brings tremendous flexibility.


Is the XTool D1 Pro 40W portable?

Yes, the engraver weighs under 15kg and can be transported or relocated around a workspace with ease. Use caution when moving it with the laser module installed.

What materials can’t be laser cut by the diode?

Transparent plastics like clear acrylic do not work with diode lasers. There are additional difficulties with some ornamental metals that have specialty coatings.

What does the 2 year warranty cover?

XTool warrants the metal, motors, and mainboard against defects for 2 years. Consumable parts like the lens and laser module have shorter 6 month warranties.

Can I operate the laser outdoors?

No, outdoor operation risks dirt or moisture infiltration damaging the sensitive optics and electronics. A tidy, interior space is necessary for the laser cutter.

Is Internet connectivity required for using the engraver?

No internet is needed – the xtool d1 pro 40w runs fully offline using standalone design software suites like XTool Creative Space and LightBurn.

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