Don’t Buy the xTool S1 for Metal Cutting Until You Read This (3 Scenarios)

When I first started looking for a desktop laser engraver for our workshop, I assumed any machine on the market could handle metal—at least the thin stuff. That assumption, I learned pretty quickly, is wrong. Or, more accurately, it's conditionally right.

Here's the thing: questions like "Can the xTool S1 cut metal?" or "Is it good for metal engraving?" don't have a single yes-or-no answer. It depends entirely on your workflow. It depends on what kind of metal, what you're trying to achieve, and what your definition of "cutting" or "engraving" actually is.

In my five years of handling equipment purchases for a 15-person product design studio, I've seen three distinct scenarios play out. Let me walk you through each one, so you can figure out where you land.

Scenario A: You Need Deep, Industrial-Grade Cutting

This is the scenario most people picture. They imagine a machine like the xTool S1 slicing through 3mm steel, square and clean, in a single pass. If that's your use case, stop reading and look at a CO2 or fiber laser. The xTool S1, even with its 40W diode module, is not that machine.

Why? A 40W diode can mark and lightly engrave some coated metals (like anodized aluminum or laser-markable stainless steel). But trying to cut through a 1mm sheet of raw steel is a losing battle. Even with multiple passes, you'll get excessive heat buildup, poor edge quality, and you'll cook your consumables fast.

I learned this the hard way. In Q2 2023, a client asked for a small batch of 50 custom metal tags. I thought my "high-power" diode laser could handle 0.8mm brass. It took 15 passes with aggressive settings, the material warped, and the edges were a mess. The rework cost more than the raw materials (Source: our internal project cost tracker, Q2 2023).

The Verdict for This Scenario

• What works: Light engraving on coated metals (anodized aluminum, powder-coated steel). Think logos or serial numbers on pre-made products.
• What doesn't: Cutting any uncoated, thick metal (more than 0.5mm) for a production-ready result.
• Better approach: A 60W+ CO2 laser with a rotary attachment, or a fiber laser MOPA unit.

If you're in this camp, the xTool S1 is not bad, it's just the wrong tool for the job. It would be like using a scalpel to chop a tree—possible? Technically, yes. Practical? Absolutely not.

Scenario B: You Want to Mark or Lightly Engrave Metal for Branding or Serialization

This is where the xTool S1, particularly with the 20W or 40W module, genuinely shines. I manage orders for about 400 promotional items and small parts across three locations annually. For the past year, I've been using an S1 for exactly this: adding logos and serial numbers to stainless steel keychains, aluminum nameplates, and brass business cards.

But here's the nuance: you need a marking spray or a specific coating. The laser itself doesn't ablate the metal (surprise, surprise—most people don't realize this). Instead, it heats a spray or the anodized layer to create a permanent mark.

How it works in practice:

1. Apply a thin layer of marking spray (like CerMark or Enduramark) to the bare metal surface.
2. Let it dry (takes about 30 seconds with a heat gun, or 10 minutes air-dry).
3. Run your job on the S1 (200-300 mm/s at 80-90% power on a 20W module works well).
4. Wipe off the residual spray. The mark is dark, permanent, and highly detailed.

This process won't cut through the metal (see Scenario A), but it creates a professional, durable mark that rivals what a $5,000 fiber laser can do for simple jobs. For a small business making custom gifts or small-batch retail products, this is a huge advantage.

The Verdict for This Scenario

• What works: High-contrast marking on stainless steel, aluminum, brass, and copper (with marking spray). Great for logos, text, and decorative patterns.
• What doesn't: Deep engraving or cutting.
• My tip: Use a 20W or 40W module. The 10W is too slow for this, and the 5W simply won't do it.

"I used to think rush fees were just vendors gouging customers. Then I saw the operational reality of expedited service. Same with marking spray—it looks like a gimmick, but it's actually the secret."

Scenario C: You're Just Curious and Have No Specific Metal Job Yet

This is the most common scenario, honestly. You're a hobbyist or a small business owner who heard the xTool S1 can "do metal" and want to know if it's worth the $1,000-$1,500 investment. My advice? Buy the machine, but don't buy it for metal work. Buy it for wood, acrylic, leather, and glass, and treat the metal capability as a bonus.

I've seen 2024's vendor consolidation projects fail because people bought a laser specifically for a use case they didn't fully understand. Get the base machine (the S1 is excellent for desktop prototyping), add the 20W or 40W module later. You'll be happier.

If you absolutely must engrave metal without spray (I get it, it's messy), you can try a 0.5mm depth of focus with a 1-second dwell time at high power. The result will be a faint, bleached mark on stainless steel (it's oxidation, not engraving). It's barely visible, and inconsistent across batches.

The Verdict for This Scenario

• What works: A minimal, "good enough" option for marking stainless steel without spray. Not suitable for customer-facing work or consistent branding.
• What doesn't: Any kind of cutting or reliable engraving on other metals.
• Better approach: Just buy the marking spray (costs about $40/bottle, lasts for 500+ applications). It's worth it.

How to Decide Which Scenario You're In

You don't need to be a laser expert to figure this out. Ask yourself these three questions:

1. Is your metal part thinner than a credit card (0.8mm) and have a coating? Yes? You're in Scenario B. No? You're likely in Scenario A.
2. Do you need the final part to be structurally cut through? Yes? Scenario A. No? Scenario B or C.
3. Is the project for a client or for internal prototyping? Client work? Stick to Scenario B (with spray)—it's professional. Internal prototype? Scenario C is fine for testing.

In my experience managing 60-80 orders annually, the people who get frustrated are the ones who buy a tool hoping it will do something it wasn't designed for. The xTool S1 is a fantastic desktop engraver. It can absolutely handle metal in the right context—it just can't do everything.

Prices as of May 2024: xTool S1 base unit $449, 20W module $399, 40W module $749. Verify current pricing at xtool.com.