I used to think diode lasers couldn't cut it.
Everything I'd read before 2020 said diode lasers were only good for marking, maybe burning thin wood – certainly not for metal engraving or cutting acrylic. I bought a cheap 5.5W unit my first year (2019) to test the waters. It could barely etch a logo onto a coaster. I ended up wasting about $450 on materials and upgrades trying to make it work. That's when I decided diode lasers were a dead end for my small workshop.
Fast forward to 2023: I picked up an xTool S1 with the 20W module almost out of curiosity. The results weren't just better – they were a different category entirely. Over the next 18 months, I added the 40W module and the rotary bundle, and now I run production orders on it while my CO₂ machine sits idle.
The moment I knew I was wrong
In January 2024, I got a rush order for 75 Valentine's Day gift boxes. Each box needed an engraved heart on a thin stainless steel plate and a small acrylic cutout glued to the lid. The customer wanted a two-day turnaround. Typically, I'd have subcontracted the acrylic cutting to a local shop (which would take 3 days and cost $320). But I decided to try the xTool S1 with the 40W module for the acrylic and the 20W for the metal engraving.
Result: All 75 boxes finished in under 8 hours. The acrylic cut cleanly at 400mm/min on a single pass. The metal engraving took longer but was consistent. Total cost in materials and electricity: maybe $12. That $320 subcontract fee? Saved. Not ideal, but workable? No – this was better than ideal.
Three reasons I now recommend the xTool S1 (especially with the rotary bundle)
1. Multi-material versatility isn't just a marketing tagline
I've personally engraved on anodized aluminum, stainless steel, glass, leather, and even slate coasters – all with the same xTool S1 body, just swapping between the 20W and 40W modules. The key difference from my old laser? The focal point is incredibly stable. No fiddling with manual focus every time I change materials. The integrated air assist (which I bought as the separate bundle) dramatically cuts down on scorching, especially on plywood.
Here's a surprise I didn't expect: The 40W module can cleanly cut 6mm acrylic at a speed that rivals my 60W CO₂ laser – with a smaller kerf and cleaner edges. The trade-off? It takes a bit longer for very thick materials (above 10mm), but for 90% of my small shop work, it's actually faster because I don't have to wait for the CO₂ tube to warm up.
2. The rotary bundle unlocked a whole new revenue stream
I ordered the xTool S1 rotary bundle (xtool s1 rotary) because I wanted to engrave cylindrical items – tumblers, wine glasses, pens. The setup took about 15 minutes the first time. My first test was a batch of 50 stainless steel tumblers for a local real estate agent. Using the roller attachment, I engraved their logo and contact info around the circumference.
The result: $1,150 order, about 4 hours of machine time. That single order paid for the entire rotary bundle. I've since run dozens of similar jobs – wine bottles for weddings, small cylindrical gift boxes for corporate clients. The biggest mistake I made early on? Not tightening the set screw enough on the roller. One tumbler slipped mid-engrave and I had to scrap it – a $12 loss plus 20 minutes. But I documented that mistake and now we have a pre-check checklist (my team hasn't repeated it in 47 orders).
3. The modular power system is smarter than I gave it credit for
When I first saw the xTool S1 could take 10W, 20W, or 40W modules, I thought: Why not just buy the most powerful one? Well, the answer is nuance. For delicate engraving on leather or very thin metal, the 10W module actually gives you better resolution – the lower power density means less heat distortion. For cutting thick acrylic, the 40W is essential. I keep both the 20W and 40W on hand (the 40W laser module for s1 is about $500 retail as of January 2025) and swap them based on the job. The swap takes 90 seconds, including re-calibrating the focus.
To be fair, I get why people just buy the 40W and call it done – but they're missing out on the fine engraving capability. My advice: start with the 20W unless you know you'll mostly cut thick materials. You can always upgrade later, and the 10W/20W modules are still useful down the road.
But what about CO₂ lasers? Fiber lasers?
I know someone reading this will say: Why not just buy a CO₂ laser or a fiber laser engraver for sale instead of messing with diode modules? Valid question. Here's my honest answer, based on 5 years of running a small production shop (I'm not a laser engineer – I'm just a guy who runs a workshop):
- CO₂ lasers are excellent for thick materials and large formats, but they're bulky, require water cooling and 220V power, and take up a lot of floor space. My xTool S1 sits on a small desk and runs on standard 110V.
- Fiber lasers (the ones you see fiber laser engraver for sale listings) are incredible for deep metal engraving and marking, but they're expensive (starting $3k+) and can't cut wood or acrylic at all.
- The xTool S1, especially with the 40W module, handles 80% of what a small business like mine needs – engraving metal, cutting wood and acrylic, personalizing gifts – all in one package under $2,000 fully loaded.
I'm not saying diode lasers will replace CO₂ for industrial production. But for a small wood laser cutter that also does metal and acrylic? The xTool S1 is the most versatile option I've found. And yes, I've used both Glowforge and OMTech machines – I'm not naming names because I respect their different strengths, but for modularity and accessory ecosystem, the xTool platform is ahead.
The real value: customer education, not specs
After three years with the xTool S1, I've come to believe that the biggest win isn't the technical specs – it's how easy the machine makes it to educate my customers. When a client comes in wanting laser cut valentines gifts, I can show them sample materials on the spot, engrave a test piece in minutes, and discuss options without confusion. The machine's speed and consistency mean I can run small batches profitably. Informed customers ask better questions and make faster decisions – they're happier and I get more referrals.
So here's my final take: If you're debating between a cheap diode laser (I've been there, wasted $450) and a premium model like the xTool S1, do yourself a favor and skip the budget route. The xTool S1, especially with the rotary bundle and a 40W module, will pay for itself in your first few big orders. I've stopped looking at CO₂ upgrades. My next move might be adding a fiber laser later, but for now, this diode machine is earning its place on my bench.
Pricing note: As of January 2025, xTool S1 base unit with 20W module is around $1,300; the 40W module is $500 extra; rotary bundle about $200. Total: $2,000. Compare that to a similar-capability CO₂ setup at $3,500+ not including fume extraction. (Prices from xTool's official store, verify current.)
