Skip to content This page contains the project files, drawings, templates and reference resources used throughout the K40 Xtreeem: K40-Style Laser Cutter Upgrade Series with Russ Sadler.
To view the full upgrade index and session overview, visit:
https://laseruser.com/k40-xtreeem-laser-cutter-upgrade-menu/
These files are provided to support users following the K40 Xtreeem rebuild and upgrade process. They are intended as reference and learning resources for engineering-minded makers undertaking similar modifications, mechanical upgrades or optics improvements to K40-style CO₂ laser cutters.
Use this page as the central download index for Russ Sadler’s K40 Xtreeem drawings and templates. The files document the project as it developed, including later revised items such as the Mk2 Issue B head and clamp drawings.
Before You Manufacture the Parts
- Measure the material you actually have. The build videos demonstrate that nominal acrylic and sheet thickness can differ enough to change tab, slot and sliding fits.
- Check the drawing revision. Where a file is explicitly labelled with a later issue or revision, use that designation when matching it to the corresponding component and video.
- Allow for the manufacturing process. Laser kerf, burrs, bend position, springback and tapping accuracy can all change the finished fit even when the CAD geometry is correct.
- Make a test part first. For locating tongues, slots, clamps and other tolerance-sensitive features, prove the fit before producing a full set.
- Observe the project-file licence. The copyright and personal/non-commercial-use terms further down this page remain applicable to these downloads.
The drawings are best treated as engineering reference files for the Xtreeem build rather than as a guarantee that every K40 chassis or replacement component will share identical dimensions.
Russ’s K40 Xtreeem Project Files – Download Area
Acrylic nameplate frame and slot cover
Acrylic nameplate
Air assist schematic
Clamp for Mk 2 Laser Head – Issue B
Clamp for Mk 2 Laser Head – Issue B Bending Details
Exhaust and Cooling box
Flexible gantry bracket and Y bearing rail
Gantry and X bearing rail
Laser Head mounting plate MK2
Keyboard mount and cover
LED light rail and voltage converter
Lightweight Laser Head Mk 2 – Issue B
Mirror 1 mount
Mirror 2 mount
Mounting Pillars
Short Laser Head Mounting Plate
Short Lightweight Laser Head for Xtreeem Rotary Unit
Targets and Holder for Mk2 Head
Thermometer holder
Tube baseplate and backplate for enclosure
Tube clamp
Tube mounting channel
Water pump and flange
Water Tank box
Xtreeem Rotary Unit
Z axis target holder and targets
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?
Did you enjoy this post? Why not check out some of our other posts:
Related Guides and Technical Resources
If you are using these project files as part of a K40 upgrade or rebuild, the resources below provide additional context on optics behaviour, cutting performance, and post-upgrade tuning:
- Laser Myths Explained – Evidence-Led Optics & Cutting Physics
Explains focal length behaviour, acrylic cutting myths, kerf formation, heat-affected cutting and real-world CO₂ laser beam characteristics.
→ https://laseruser.com/laser-myths-explained/ - How to Align a Laser Beam
A structured alignment and calibration workflow covering mirrors, beam path stability, tolerance compensation and repeatable setup after mechanical changes.
→ https://laseruser.com/how-to-align-a-laser-beam/ - K40 Xtreeem Upgrade Series Menu
Browse every session in the K40 Xtreeem project including mechanics, tube mounting, optics alignment, controller upgrades, wiring and commissioning.
→ https://laseruser.com/k40-xtreeem-laser-cutter-upgrade-menu/ - Compatible Lenses, Mirrors and Upgrade Components
OEM-compatible lenses, mirrors, mounts and assemblies suitable for K40-class and compact CO₂ gantry laser systems.
→ https://laseruser.com/shop/
These resources help relate the downloadable project files to the engineering principles and performance outcomes they support in the wider K40 Xtreeem upgrade journey.
© Copyright Notice for K40 Xtreeem Project Files:
Copyright © 2022 Russ Sadler
This website and its content is copyright of n-Deavor Limited – © n-Deavor Limited 2020-2022. All rights reserved.
The K40 Xtreeem Project files is copyright of Russ Sadler – © Russ Sadler 2022. All rights reserved.
Any redistribution or reproduction of part or all of the contents in any form is prohibited other than the following:
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Disclaimer
Last updated April 25, 2024
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