@JimH I understand what you’re saying, and just want to confirm, that I have been a Mafell fan for a long time, still am, and own Mafell tools.

I have heard similar though, regarding the latest machine. The switch issue, and the plunging isn’t a great experience are what quite a few reports suggest.
I was hoping the machine would offer more than just the shelf pin function, over the dowelling. As I’m not a big fan of dowel joints, and if the truth were known, I don’t think some of my customers would be.
It seems though, that even the shelf pin function is only at it’s best, when used with the optional jig?
I can’t help thinking that this machine was designed to take sales away from the Domino. There’s no comparison though (in my opinion) The Domino is unique in many ways.

I know people that own the original doweler, and they have never that I know of, had problems.

My next Mafell will be either a P1, as I have lots of use for one, or an Erika for the same reasons.

After the DDF 40 died I turned to the Domino 500 to join particle board panels. In addition to finishing the project I wanted to compare ease of use and productivity of the DDF 40 and Domino. Everything about using the doweler was easy, except the actual drilling of dual 8mm holes.

The included guides allowed me to position the Duo without measuring so I worked the same way with the Domino whereas I usually mark positions of tenons. To be fair I used the narrow mortise setting. I even used raw ended Dominos instead of beveling the ends like I’d planned.

The Domino was significantly more productive. The panels went together almost as easily as with dowels. I expect if I’d beveled the tenons it would have been equally easy. The tight mortises did not present an alignment issue but some thanks goes to the less softness of particle board.

All in all I’m glad to have had the chance to work with the machine but I’m relieved that it died and I’ll get a refund. I can use the money for a different Mafell that will be more useful.

One last footnote, maybe it wasn’t just be the switch that failed. It might be another component that possibly prevented the bits from running at the full 8000 rpm. The Domino is much louder than the DDF 40 was...

As a first time Mafell buyer with the DDF, I have conflicting emotions.

On the disappointment side, the tool takes an inordinate amount of force even in soft wood like pine. I normally build with oak or walnut, so I am worried about how usable the tool will be.

On the positive side, the tool is amazingly precise, well built, and equipped with excellent accessories. It really complements my two Domino machines. Also positive is the helpful attitude of the Timberwolf staff..

For now, I have decided to keep the machine for testing with oak and walnut. I also bought some 10mm bits I want to try. If I can use the machine with those wood types and the 10mm bit, I’ll keep it.

After using the DDF, I wish Festool would offer the pin locators on the Dominos instead of the flappers.

The original Domino did indeed have the same (almost) metal pin locators as the Mafell. It just that they used them in contravention of the Mafell Patent and were taken to court. They lost.

That is why the new Domino's have the awful flappers and why I will never ever get rid of my original Domino with its excellent, but illegal, metal pins!

The original pin type were better but, when I bought a later Domino with the paddles, I never had or have issues with them. I prefer the pins given the choice but, the paddles work fine for me also.

I have an old one with pins Doug, and the later paddle type, I got on fine with pin version but, they can as you say snag up. The pins are probably more durable than the paddles being metal but, I get on fine with the later paddle type machine just fine.

I am a long time Domino user (both models). I always use the narrow and wide technique on joining long boards.

I tried the DDF40 on joining 48” long boards using just the machine and its accessory (little plastic tabs).

The boards joined perfectly.

I’m keeping my 2 Domino machines, but I’m sold on the DDF40 as a very specialized machine.

I’ll view the significant push effort as a body building exercise.

My DDF40 was plugged directly into a wall socket.

I used the Domino 500 to join 30” panels (at the tight setting with 5mm tenons) using the onboard pins and the wings and the panels joined fine but the wood was just particle board. If working with real would I’d use the medium width setting for most of one of the boards.

Bits are 55mm long, have an 8mm shank with a flat. The 5mm CMT bits I bought (about $9 $11 each at routerbitworld) are only around 53.5mm long. The machine’s socket is round with a set screw in the middle.

Wonder is the flat would disallow the bits to be used in a router collet?

I called Timberwolf about my DDF 40 that stopped running. Spoke with Jeff. He was surprised by the failure and apologized. There is no problem returning the tool for a refund. He promptly emailed a pre-paid FedEx shipping label.

Jeff was very pleasant to deal with and I’ll probably buy another Mafell shortly.

Returned the tool in the same packing it arrived in, a strong triple wall cardboard box and bubble wrap surrounding the dressy Mafell cardboard carton that held the Mafell Sys 2, and the special foam wedge that prevents plunge movement of the machine. Despite all that the jostling of transit was apparently therapeutic.

“We received your Mafell DDF 40 Duo Dowel System back today.  It was able to turn on when I plugged it in, but there was some noticeable fluctuation in the motor.  I opened up the motor and did not notice anything unusual—except the spring that pushes in one of the carbon brushes was slightly out of place.  When I moved it back to its proper place the machine sounds perfect. I’ll keep the machine here in Chicago as a demo—we could always use another for walk-ins!“

@Jiggy Joiner  it would have been an easy fix (as it turns out) but by the time the unresponsiveness of the switch became intolerable I’d already decided the tool wasn’t going to be useful enough (for what I do) to keep it so I didn’t want to risk the refund by messing with it.

I took Jeff’s response to be It was a very minor misfit that caused no damage and it’s all good now so do you want it back?

I've had mine about month and have only used it a couple of times.  I haven't had any issues with the plunge being difficult and I was plunging into plywood.  It does have a qualify look and feel to it.  It's a fine addition to the workshop. 

The guy at Timberwolf told me to expect that exact thing. 

@ DeformedTree I don't think you have any worries with Mafell, my experiences with them have all been positive, bearing in mind that they are quite a small company with limited outlets.
They aren't fast at answering email but, neither are Festool in my experience, in fact I have at least two unanswered emails to Festool.
Timber Wolf seem a decent dealer, so again you should be fine.

As for 110v V 240v, all I can say is, I own, and have owned in the past many tools in 110v for our mobile and site work, and a lot of 240v. I have quite a few tools that are identical in both voltage. I have found that the many show the 240v to be more powerful/faster. Running certain tools side by side it's quite noticeable, however, that may be, because over here we use step down transformers, and obviously the length of an extension lead would also have an effect.

I have run a 110v mitre saw against an equivalent 240v version, angle grinders, table saws, etc, and the 240v's seem faster? Some of the smaller tools, like sanders etc, don't seem any different, or at least not noticeable. The only tool I can't tell any difference with are the Festool CTM 26's, they sound and seem to perform the same in both voltage.

I haven't done any scientific tests but, you can hear and feel the 240v tools are running faster.
Could well be, and probably is a different story on your side, as you don't need transformers.