This article is part of the K40 Xtreeem: K40-Style Laser Cutter Upgrade Series with Russ Sadler.
View the full upgrade index and session overview here:
About the K40 Xtreeem Laser Cutter Upgrade Project
The K40 Xtreeem project documents a complete performance-focused engineering upgrade of the popular low-cost K40-style CO₂ laser cutter. Rather than treating the K40 as a disposable entry-level machine, this series approaches it as a configurable laser platform — examining how changes in mechanics, optics, cooling, electronics, airflow, and beam delivery translate into measurable improvements in cutting and engraving performance.
Each stage of the upgrade path is supported by real-world testing, practical demonstrations, and physics-based reasoning. The objective is not to cosmetically modify the machine, but to show how specific engineering decisions influence:
- Cutting speed and process stability
- Kerf width, edge quality, and consistency
- Repeatability, alignment tolerance, and mechanical accuracy
- Beam delivery, focal behaviour, and energy density
- Thermal performance and long-term system reliability
This series is designed for K40 owners who want to extract meaningful performance improvements from their machines, as well as educators, hobby engineers, and technical users who want to understand how system-level changes affect CO₂ laser behaviour. The sequence is structured so that each upgrade delivers standalone value while also contributing to a fully optimised end-to-end system.
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K40 Xtreeem Upgrade Series — Session Index
Follow the project in sequence or jump directly to the engineering stage that interests you.
Session 01 – K40 Xtreeem Laser Cutter; Upgrading The Mechanics (37:02)
Removing the factory XY frame and replacing it with a stiffer, precision-aligned gantry and linear-bearing assembly, together with a new tube mount and first-mirror solution.
Session 02 – K40 Xtreeem Laser Cutter; Changing The Controller (48:21)
Removal of the original analogue electronics and installation of a Ruida controller, updated control panel, new stepper drivers, revised PSU layout, and milliammeter relocation.
Release Date: 24th May 2022.
Session 03 – K40 Xtreeem Laser Cutter; Integrating The Utility Upgrades (51:49)
Bringing together the mechanical and electrical changes and introducing a portable service station for power delivery, cooling, water storage, extraction airflow, and air assist.
Release Date: 31st May 2022.
Session 04 – K40 Xtreeem Laser Cutter; Finishing The Build And Machine Setup (56:56)
Final assembly, beam alignment, tube performance checks, and machine-setup refinements prior to commissioning.
Release Date: 7th June 2022.
Session 05 – K40 Xtreeem Laser Cutter; Optimising The Performance (30:01)
System calibration, acceleration tuning, and practical speed-performance validation following the mechanical and control upgrades.
Release Date: 14th June 2022
Session 06 – K40 Xtreeem Laser Cutter; Let’s Put It To The Test! (52:20)
Photo engraving and cutting performance evaluation using challenging materials such as slate and cardboard, together with comparative benchmark testing.
Release Date: 21st June 2022
Session 07 – Let’s Build a K40 Xtreeem Rotary Attachment – Pt 1 (43:15)
Designing a practical rotary solution within the physical constraints of the K40 chassis, avoiding floor-cut modifications and enabling compact rotary operation.
Release Date: 28th June 2022
Session 08 – Let’s Build a K40 Xtreeem DIY Rotary – Pt 2 (39:59)
Rotary refinement, lightweight head redesign, shortened lens tube and nozzle options, Y-axis manual home function, and final test integration.
Release Date: 28th June 2022
Tools, Components, and Supporting Hardware
Many of the upgrades demonstrated in the K40 Xtreeem project involve improvements to optics, beam alignment, wiring, cooling, mounting structures, and mechanical integration. Where appropriate, the project references compatible components that support reliable, repeatable performance during and after the upgrade process.
Typical parts and accessories used throughout the series include:
- Replacement CO₂ laser lenses for a range of focal lengths and cutting applications
- High-quality first-surface mirrors to improve beam delivery stability
- Precision mounting hardware and optical holders for accurate alignment
- Laser power meters for calibration, setup verification, and performance tracking
- Ancillary items such as improved connectors, cabling, airflow modules, and cooling support hardware
For users who wish to replicate or extend the upgrades shown in this project, a range of compatible lenses, mirrors, optics assemblies, and measurement tools are available from the Laserhttps://laseruser.com/shop/User store.
Browse compatible lenses, mirrors, and laser accessories
Using the right components — combined with accurate alignment and evidence-based configuration — enables even a modest K40-style platform to achieve significantly higher cutting quality and operational consistency than its factory configuration.
Browse compatible lenses, mirrors, and laser accessories
Using the right components — combined with accurate alignment and evidence-based configuration — allows even a modest laser platform such as the K40 to deliver performance far beyond its factory capability.
Addendums
K40 Xtreeem Laser Cutter Project Files
Download the drawings and reference files used to manufacture the components demonstrated in the video series. Please note: files reflect the versions used during development and may be updated where future manufacturing refinements are required.
Please note: These are the drawings Russ used for the components used in the videos. They are subject to updates based on future part manufacturing requirements.
Preparing the K40 Xtreeem Mechanical Kit (51:31)
A detailed walkthrough of the mechanical kit assembly, including fixings, brackets, rails, and sub-assemblies. Ideal for users manufacturing their own components for personal use.
Summary of Fixings for the K40 Xtreeem Mechanical Kit (08:43)
Overview of the principal hardware elements included in the mechanical kit. Limited pre-assembled kits are available on a first-come-first-served basis via direct enquiry.
Please note: Russ will be manufacturing a number of mechanical kits as a one off project. These will be of a limited quantity and supplied on a first come first served basis. If you wish to purchase a mechanical kit, please use the contact form below. This will put you directly in touch with Russ.
Want To Make An Enquiry To Russ Regarding Parts Or You Have Questions About This Project?
Then Just click on the link below, which will open up an information request form.
What Next?
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Related Guides and Resources
If you are upgrading or rebuilding a K40-style CO₂ laser cutter, the following resources provide additional engineering-focused guidance on optics, cutting performance, and system behaviour:
- Laser Myths Explained – The Physics Behind Better Cutting
Evidence-led explanations of common CO₂ laser cutting myths, including focal length behaviour, air-assist assumptions, intensity focus, and real-world beam physics. - Diode Lasers Explained – Under the Hood Guide
A deep technical guide to diode laser behaviour, covering optics, modulation, thermal limits, signal timing, and practical engraving performance. - K40 Xtreeem Upgrade Series Menu
See all sessions in the K40 Xtreeem project, from mechanical rebuild and tube mounting through to controller upgrades and beam alignment. - Compatible Lenses, Mirrors, and Laser Accessories
Browse OEM-compatible lenses, mirrors, optical assemblies, and upgrade components suitable for K40 and other compact CO₂ gantry laser systems.
These resources help connect the practical mechanical work in this session with the underlying optics, physics, and component choices that ultimately define cutting quality and reliability.
Do I need all of the K40 Xtreeem upgrades, or can I implement them in stages?
The upgrade path is deliberately modular. Each stage delivers measurable benefit on its own — for example, mechanical stability, controller precision, or improved optics — while also contributing to a stronger end-to-end system when combined. Many users choose to complete the mechanical and alignment upgrades first, then move on to electronics, airflow, and performance tuning.
Is the K40 Xtreeem project intended for beginners or advanced users?
The series is suitable for technically minded K40 owners, hobby engineers, educators, and enthusiasts who want to understand why an upgrade improves performance rather than simply following cosmetic modifications. The videos explain the engineering rationale behind each change, supported by testing and practical demonstrations.
Can these upgrades be applied to other small CO₂ laser cutters, not only the K40?
Yes — although the physical chassis differs between machines, the underlying principles are universal. Mechanical stiffness, optical alignment, beam delivery accuracy, cooling, airflow, and control behaviour affect all gantry-style CO₂ laser systems. Many of the ideas demonstrated in the K40 Xtreeem project can inform upgrades on other compact laser platforms.
Do I need specialist tools or machining capability to complete the upgrades?
Where possible, the project demonstrates approaches that can be achieved using basic workshop tools and readily available components. Some elements can be fabricated using drawings provided in the project files. Users with access to CNC or precision tooling may produce tighter tolerances, but it is not a prerequisite for completing the upgrades.
Will these upgrades increase cutting power or laser tube output?
The upgrades do not change the fundamental wattage of the laser tube. However, improvements in alignment, optical efficiency, stability, airflow, and beam delivery typically result in higher effective cutting performance, better energy use, and more consistent results across the working area.
Is a rotary attachment essential for the K40 Xtreeem build?
No — the rotary attachment covered in Sessions 07 and 08 is optional. It is designed for users who want to extend the machine to cylindrical work while staying within the physical limits of the K40 chassis. The core upgrade path is fully functional without the rotary system.
Where can I obtain parts or components used in the project?
Where appropriate, the series references compatible lenses, mirrors, optics assemblies, mounting hardware, measurement tools, and ancillary components. A selection of suitable items is available via the LaserUser store for users wishing to replicate or extend the upgrades demonstrated in the project.
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Last updated April 25, 2024
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