15 verified settings · manufacturer data · diode laser · Updated January 2026
| Operation | Speed (mm/s) | Power (%) | Passes | Air Assist | Notes |
|---|---|---|---|---|---|
| engrave | 100 | 20% | 1 | — | — |
| fill | 200 | 25% | 1 | — | — |
| score | 50 | 60% | 1 | — | — |
The xTool D1 Pro cuts 1/25"(1mm) Green Anodized Aluminum cleanly at 100 mm/s with 20% power. Because the D1 Pro is available in multiple wattage variants (40W, 20W, 10W, 5W, 2W), settings are grouped by wattage above — select your laser's wattage to see the right numbers. Always test on a scrap piece first — every machine is slightly different, and variables like tube age, lens condition, and material batch can shift results.
For 1/25"(1mm) Green Anodized Aluminum, the key variables to dial in are speed and power. If the laser isn't cutting through cleanly, slow down or add a pass before pushing power higher — excessive power causes charring and wider kerfs. Air assist is highly recommended for wood and organic materials to clear smoke and protect the lens.
Once you find settings that work, save them in Laser Lab to build your personal settings library. The AI predictor uses your calibrated results to suggest starting points for new materials automatically — so the more you log, the smarter it gets.
For cutting 1/25"(1mm) Green Anodized Aluminum on the xTool D1 Pro, start at 100 mm/s speed and 20% power. These are manufacturer-verified starting points — always test on scrap first.
Air assist is strongly recommended when cutting 1/25"(1mm) Green Anodized Aluminum. It clears smoke from the cut path, reduces charring, and helps protect your laser lens.
The manufacturer recommends 1 pass to cut through 1/25"(1mm) Green Anodized Aluminum at 100 mm/s and 20% power. If the cut isn't clean, try reducing speed slightly before adding more passes.
Incomplete cuts are usually caused by incorrect power, speed, or focus distance. If edges are charred, try increasing speed or reducing power. If the laser isn't cutting through, reduce speed or increase power — or add an extra pass. Also verify your focal distance is correct for the material thickness and that your lens is clean.
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