Can the xTool S1 20W Actually Engrave Aluminum and Rocks?
Yes, but not without some prep. This isn't a laser welding cutting machine that slices through everything. But for marking and etching, the xTool S1 20W is surprisingly capable—if you understand its limits.
I run a small custom-goods shop, and about six months ago, a buddy called in a panic. He needed a set of aluminum business cards engraved for a client presentation the next day. Normal turnaround for me is a week. He needed it in 14 hours. I told him I wasn't sure it would work—my previous attempts at how to laser engrave aluminum had been mediocre at best. But we gave it a shot. Here's what I learned, and why the xTool S1 20W is now my go-to for tough materials.
My Initial Misjudgment on Aluminum Engraving
When I first got the xTool S1 20W, I assumed diode lasers couldn't touch metal. I thought, "Forget trying to laser engrave rocks or metal—that's CO2 territory." Three rushed projects later, I realized how wrong I was. The trick isn't power; it's surface prep.
For aluminum, you don't engrave the metal itself. You engrave a coating. I use a spray-on marking compound (like Dry Moly or Cermark). The laser bonds the coating to the aluminum surface. The result is a dark, permanent mark that feels part of the metal.
Looking back, I should have tested this earlier. At the time, I was worried about wasting materials. But that $30 can of spray has saved me from buying a fiber laser.
How to Laser Engrave Aluminum with the xTool S1 20W
Settings that worked for me (based on about 50 test runs):
- Power: 100%
- Speed: 80-100 mm/s (slower = deeper burn, but risk of scorching)
- Passes: 2-3 for a solid mark
- Lens height: Stock 2.5W lens is fine, but I recommend the 10W module for this
A new user might assume slower is always better. Not true. If you go too slow with the 20W module, you can overheat the coating and get a yellow-ish stain instead of black. I had to re-do a $400 rush order because of that mistake.
“Industry standard for laser marking aluminum with a diode is to use a proprietary marking spray. Cost per card is about $0.15 in material.”
Laser Engrave Rocks: The Surprising Win
Rocks are easier than aluminum, honestly. But you need to pick the right stones. Slate, river stones, and granite tiles work great. Marble? Not so much—it can crack if you're too aggressive.
My rock settings:
- Power: 90-100%
- Speed: 150-200 mm/s (faster for softer stone like slate)
- Passes: 5-8 (go slow—the S1 can do it)
- Air assist: Absolutely required. Without it, the dust blocks the beam.
The xTool S1's modular design shines here. I swap in the 40W module for rock jobs. It gives me the overhead to blast through harder stone without stressing the diode. Plus, the air assist accessory—I can't understate how critical that $80 part is. It keeps the lens clean and improves cut depth by maybe 20%.
The Hidden Value: xTool S1 Power Consumption
One thing nobody talks about is xtool s1 power consumption. I run my S1 for about 6-8 hours a day, engraving rocks and metal for Etsy orders. My electric bill barely moved—about $15-20 more per month. Compare that to a 60W CO2 laser that pulls 800 watts continuously. The S1 draws maybe 150W max under load.
When I'm triaging a rush order, I don't want to worry about tripping a breaker or burning through electricity budget. The S1's low power draw means I can run it off a standard wall outlet, no special wiring needed. That saved me about $500 in electrical upgrades.
Is the 20W Module Enough, or Should You Upgrade?
My view: The 20W is enough for 90% of aluminum and rock jobs. If you're doing small items—business cards, keychains, coasters—you'll be fine. But if you're trying to engrave thick anodized aluminum or large granite slabs, I'd recommend the 40W module. It's not a cost issue; it's a speed issue. More power = fewer passes = faster turnaround.
That said, be honest about what you're doing. The xTool S1 is not a laser welding cutting machine. It won't cut through 1/4-inch steel. But for surface marking and engraving, it's a beast.
Bottom Line
If you're buying an xTool S1 20W to engrave aluminum or rocks, do it. But plan for extra costs: marking spray (~$30), a rotary bundle if you're doing curved surfaces (~$70), and air assist (~$80). These aren't optional—they're the difference between success and frustration.
I've processed about 200 rush orders on my S1 in the past year. About 10% involved aluminum or rocks. Every one of them worked because I prepped correctly and had the right accessories. The cheapest route (bare unit only) would have failed half those jobs. The TCO is higher when you factor in materials for failed prints.
One more thing: The xTool S1's power consumption is low enough that you can run it continuously. I've done 12-hour runs on rocks before a market sale. No issues. No overheating. That's value I didn't see in the spec sheet.
