Can the xTool S1 Cut Metal? xTool S1 40W Diode Laser vs CO2, Plasma, and CNC

The Real Question: Can the xTool S1 Cut Metal?

Short answer: no, not if you mean slicing through steel plate. The xTool S1 40W diode laser can mark or engrave some metals with the right prep—anodized aluminum, coated stainless steel, or metal treated with laser marking spray. It can cut wood, acrylic, leather, fabric, paper, cork, and similar materials. But 'can the xtool s1 cut metal?' in the sense of cutting sheet metal? No. And that's okay, because it's not the right test for most small shops.

I'm a procurement manager at a 14-person small-batch manufacturer. I've managed our equipment budget for six years, negotiated with 30-plus vendors, tracked over $180,000 in cumulative spending, and built a TCO spreadsheet that has saved us from more than one bad purchase. When we needed a versatile cutting and engraving tool, I compared four machines that compete for the same money: the xTool S1 40W diode laser, a 60W CO2 laser, a hand held plasma cutter, and a CNC router.

Let me define 'cut' first. If a machine can remove material through the full thickness reliably, that's cutting. Marking and engraving are not cutting. That distinction is where most of the confusion starts.

Dimension 1: Material Capability—Where Each Tool Actually Wins

Here's the comparison that matters:

• xTool S1 40W diode laser: Cuts wood, acrylic, leather, paper, fabric, cork. Engraves coated or anodized metal. Does not cut bare sheet metal.
• CO2 laser (60W): Excellent for wood, acrylic, and fabric. Also doesn't cut steel. With metal marking spray, it can engrave some metals, but it's not a metal-cutting machine.
• Hand held plasma cutter: Cuts steel, stainless steel, and aluminum using an electric arc and compressed air. It won't touch wood or acrylic.
• CNC router: Cuts wood, plastics, and soft aluminum with the right bit, feeds, and speeds. Not for steel.

Everything I'd read before this purchase said diode lasers are underpowered. In practice, the 40W S1 handled our thin acrylic and wood far better than I expected. It's not a CO2 replacement for heavy production, but it's not a toy either.

The most frustrating part of comparing these machines is wattage. A 40W diode's optical output isn't the same as a 40W CO2 tube's output. You'd think 'watt' would be a controlled unit, but in the laser world, it's full of marketing math.

Dimension 2: Wood and Acrylic—CO2 Laser Holz Schneiden vs xTool S1

If you've searched for 'co2 laser holz schneiden'—German for CO2 laser wood cutting—you already know why CO2 lasers have a following. They're genuinely excellent at wood and acrylic. A 60W CO2 tube cuts through thicker materials in one pass and leaves clean edges. A diode laser needs multiple passes and prefers thinner material.

For our actual workload—small-batch wood signs, acrylic keychains, leather tags—the 40W S1 handled the majority of jobs. Thicker pieces still needed slower speeds and extra passes. If I were running a sign shop with production volume every day, I'd buy the CO2. For mixed small-batch work, the S1's flexibility mattered more than raw speed.

The modular design also changed the TCO equation for me. The ability to swap between 10W, 20W, and 40W laser modules means you can match the core machine to the job without buying a second unit. In my experience, modularity is worth something even if you don't use it every week.

Dimension 3: Running Costs and Consumables

This is the part I care about most because a lower sticker price can hide a budget-killer. I learned that the hard way. A coworker once convinced me to buy a cheap CNC router based on the initial quote. We didn't budget for collets, dust collection, endmills, or the learning curve. That 'cheap' machine ended up costing roughly 40% more than the mid-range alternative I'd initially dismissed. Since then, every equipment purchase goes through the same TCO process.

From my expense tracking:

• xTool S1 40W: Consumables are modest—air assist filters, cleaning supplies, and the eventual replacement of the laser module. Electricity draw is low compared to CO2.
• CO2 laser: The tube has a finite life, and a replacement tube can cost several hundred dollars. Add chiller maintenance, cooling fluid, optics cleaning, and exhaust filter replacement.
• Hand held plasma cutter: Consumables include electrodes, nozzles, and shields. You also need clean, dry compressed air. Sparks and slag wear consumables fast.
• CNC router: Bits are the killer. A decent endmill can last hours, not months, and one bad hit snaps it instantly.

Rough numbers from our shop: the S1 cost about $1–2 per hour including electricity and consumables. The plasma cutter was closer to $3–5 per hour. The CNC router was the most unpredictable—sometimes $1, sometimes $8, depending on whether an endmill survived the job. Take these estimates with a grain of salt; your shop's usage will vary.

The lowest quoted price isn't the lowest total cost.

I've written that in every procurement review for the past four years, and it's never been wrong.

Dimension 4: Setup, Safety, and Space

This is where I almost made a $1,200 mistake. I had requested a quote for a 60W CO2 laser before I realized it needed a dedicated exhaust vent, a chiller, and more floor space than we had. So glad I didn't pull the trigger. The xTool S1 fits on a workbench, has an enclosure, and still needs proper ventilation—but it doesn't need a chiller or a permanent duct through the wall.

Don't read 'enclosed desktop laser' as 'safe with zero thought.' You still need fume extraction and proper operating habits. Laser safety isn't the place to save money.

Plasma cutters are a different animal. They create an electric arc, sparks, molten metal, and fumes. You need serious ventilation, a fireproof work area, and protective gear. CNC routers are loud and kick up fine dust; you'll want dust collection and hearing protection. Every one of these machines has a hidden cost in safety equipment and shop modifications. That cost should be in the comparison, not an afterthought.

Dimension 5: Software and Learning Curve—CNC Router vs Laser Engraver

The cnc router vs laser engraver comparison isn't just about the cutting mechanism. It's about the workflow. A laser engraver works almost like a printer: send a file, set power and speed, press start. A CNC router expects you to think about chip load, bit deflection, climb cutting, tramming, and fixturing. If you're new to CNC, the learning curve is steep.

The xTool S1 runs with xTool Creative Space, which is beginner-friendly, and it can also work with LightBurn if you want more advanced control. CO2 lasers also run well with LightBurn. Plasma cutting is more of a manual skill—there's no 'file to part' workflow in the same way.

For a small business, time to first successful part matters. In my opinion, a laser wins that race almost every time. That doesn't make lasers 'better' than routers; it makes them easier to get value from quickly.

Dimension 6: 18-Month Total Cost of Ownership

Let's do the math the way I'd do it for a purchase request. These ranges are based on publicly listed prices I checked in January 2025 plus my own tracking. Bundle prices change, so don't hold me to exact figures.

• xTool S1 40W bundle with rotary and air assist: roughly $1,500–$2,500 initially. Add modest consumables and a basic ventilation setup. 18-month TCO: maybe $3,000–$4,500.
• 60W CO2 laser: roughly $2,500–$4,500 initially. Add exhaust, chiller, and a tube replacement reserve. 18-month TCO: $5,000–$8,000.
• Hand held plasma cutter: $800–$2,000 initially, plus compressor, consumables, and safety gear. If steel cutting is limited, TCO can stay reasonable, but it doesn't replace the laser functions.
• CNC router: $1,000–$3,000 initially, plus bits, dust collection, software, and learning time. Bits and breakage push the TCO higher than people expect.

The exact numbers matter less than the framework. If you already own a compressor, the plasma TCO drops. If you cut thick wood daily, CO2's speed pays for itself. If you need custom engravings on wood, acrylic, and coated metal without giving up your whole workshop, the S1 is the smart total cost play.

What I'd Buy, and What I'd Skip

If you're a maker or small business owner and you keep asking whether the xtool S1 can cut metal, I'd reframe the question: do you actually need to cut metal, or do you need to add value to metal? If cutting steel is a daily job, buy a hand held plasma cutter—and possibly a CNC router for non-metal work. If you need a versatile engraver and cutter for wood, acrylic, leather, and occasional metal marking, the xTool S1 40W diode laser is a strong first machine.

CO2 lasers are still excellent for wood-heavy production. But for a small shop with limited space and a real budget, the S1 might be the better total cost decision. And if you're weighing cnc router vs laser engraver, choose based on your material and your patience for toolpaths.

I'd rather spend 10 minutes explaining these options than deal with mismatched expectations later. An informed customer asks better questions and makes faster decisions. So, can the xTool S1 cut metal? No. But it might be the most cost-effective way for a small shop to do metal engraving—and that's the question you should actually be asking.