If you're serious about getting into laser engraving—and I mean serious enough that you're already pricing out an xTool S1 with the 40W module and a full accessory bundle—here's the hard truth: your total cost is going to land between $1,800 and $2,600 depending on the module, the rotary, and whether you build your own enclosure. And honestly? For most small business owners and makers, you should start with the 20W module, not the 40W. Here's why.
Why I'm Qualified to Say This
I'm a procurement manager at a 15-person product design and prototyping company. I've managed our equipment and materials budget ($180,000 cumulatively over 6 years) and negotiated with over 20 vendors in the laser and CNC space. When we bought our first diode laser engraver in 2023, I did a full total cost of ownership (TCO) analysis across 4 different systems.
So when I talk about the xTool S1, I'm looking at it through the lens of a budget I have to justify to my boss every quarter. That changes how you look at things like module upgrades and 'essential' accessories.
The Core Conclusion: Start with the 20W
For 80% of small business and maker use cases, the 20W module is the sweet spot. The 40W module is faster on thick acrylic and can cut slightly thicker materials, but the extra $400–$500 is wasted if your primary jobs are engraving tumblers, cutting 3mm wood, and making signs.
I'm not a laser physics expert, so I can't speak to the exact beam profile differences between the 10W, 20W, and 40W modules. What I can tell you from a procurement perspective is that the 20W module handles 95% of the jobs that come through our shop—and the 40W only saves us time on about 15% of our cutting jobs.
Here's the math I ran for us:
- 20W module: Cuts 3mm basswood in 1 pass at 15mm/s. Cuts 5mm acrylic in 2 passes.
- 40W module: Cuts 3mm basswood in 1 pass at 25mm/s. Cuts 5mm acrylic in 1 pass.
The speed difference is real, but unless you're running production volumes (like 500+ pieces a month), the time saved doesn't justify the extra cost. That $400 buys you a lot of material to experiment with.
The Cost Nobody Talks About
When we first spec'd out the xTool S1 for our shop, I made a classic mistake. I looked at the base unit price ($599 for the machine, $499 for the 20W module, $799 for the 40W module) and thought “Okay, that's about $1,100 for a capable setup.”
Then I started adding up the actual cost of a usable system:
- Base unit with 20W module: $1,098
- Air assist: $79 (almost mandatory—without it, your cuts are charred and slow)
- Honeycomb panel (the xTool one is laser-cut to size): $79 if you buy the official 5-pack or $39 for a single. The honeycomb size is 389x395mm, by the way.
- Rotary bundle (for tumblers and bottles): $229
- Enclosure or ventilation: This is where it gets expensive. A proper enclosure with exhaust fan runs $200–$400. Or you build one for $100 in materials.
From the outside, it looks like a $1,100 purchase. The reality is a $1,500 to $1,800 purchase for a fully functional setup. That's a 30–40% hidden cost that's rarely mentioned in the flashy YouTube unboxing videos.
I'm not saying this to discourage you—I'm saying this so you budget for it. When I audited our 2023 spending, I found that 22% of our 'budget overruns' on new equipment came from missing these kinds of auxiliary costs.
Multi-Material Capability: The Real Differentiator
Compared to a CO₂ laser system—say, a budget 60W K40 or an OMTech—the xTool S1's real strength isn't power. It's versatility. A CO₂ laser will cut acrylic and wood faster. But it won't engrave metal (you need a marking spray or a fiber laser). It struggles with dark glass. It's bulkier and requires more complicated ventilation.
The diode laser in the xTool S1 handles:
- Metal: Direct engraving on anodized aluminum, stainless steel, and titanium. Not deep cutting, but permanent marking.
- Acrylic: Clear and colored acrylic up to 8mm with multiple passes on the 40W.
- Wood: Cuts and engraves cleanly across all densities from balsa to hardwood.
- Leather: Cuts and engraves beautifully. No chemical burning like some CO₂ systems.
- Glass: Frosted engraving with wet paper or direct marking spray.
- Stone and slate: High-contrast engraving.
That's a ton of capability from a desktop unit that weighs under 15kg. If you're a maker who wants to experiment across materials without maintaining 3 different machines, the S1 is a compelling choice.
People assume the 40W module will let you 'upgrade' into a metal cutter. What they don't see is the thermal limitation of diode lasers. At 40W, you're still not cutting 1mm steel sheet. You're just engraving it slightly faster. The real advantage of the 40W is in thick acrylic and dense hardwoods. For metal engraving, both the 20W and 40W perform similarly.
When the xTool S1 Is NOT the Right Answer
I recommend the xTool S1 for most small businesses and solo makers. But here's where you might want to consider alternatives:
- You need production-level cutting throughput: If you're running 8-hour shifts cutting acrylic parts, a CO₂ laser (like the xTool P2 or a generic 60W) will be 3-4x faster for the same initial investment. The S1's diode laser is precise but slow on thick cuts.
- Your primary material is clear acrylic: Diode lasers struggle with clear materials. The blue light passes through rather than burning. You can mitigate this with marking spray or paint, but it adds cost and steps.
- You need deep engraving on metal: The S1 will mark metal, but it won't cut it or produce deep pockets. You're looking at a fiber laser for that.
- Your budget is under $800 total: Honestly, if you can't afford the full setup with air assist and ventilation, you'll have a frustrating experience. The 'cheap' option of just the bare machine often results in a $1,200 redo when quality fails or you need accessories later.
I've seen people assume that because the base unit is 'only $599', a laser engraver is a cheap hobby. The reality is a fully capable system costs closer to $1,500. That's not a complaint—it's a warning. If you budget for $1,500 and get a system for $1,100 (on sale), you're happy. If you budget for $600 and get a shock at checkout, you're resentful.
One More Thing on Alternatives
Online, you'll see comparisons to other diode lasers and even some CO₂ systems. I'm not going to pick on specific brands—that's not my style. But I will say this: evaluate based on your specific needs, not specs on a datasheet. A 40W output from one brand may not be equal to a 40W from another. Look at engrave area, software compatibility (LightBurn is the gold standard), and warranty policies.
This pricing was accurate as of January 2025. The laser market changes fast, so verify current rates before buying.
So, would I buy the xTool S1 again? Yes. With the 20W module. And I'd build my own enclosure to save $200.
