Let me save you the clickbait: there's no single "best" xTool S1 configuration. Anyone telling you otherwise probably hasn't triaged a rush order where the wrong module meant a missed deadline.
I've been on the buyer side of these decisions for about five years now — coordinating custom parts for small production runs where turnaround time matters more than perfection. I've seen setups that made money on day one, and others that gathered dust because the buyer picked a configuration that didn't match their actual work mix.
So instead of giving you one recommendation, I'll walk you through three real scenarios I've encountered. Figure out which one sounds like your operation, and that's your answer.
Scenario A: The Prototype & Light-Duty Workshop
This is the most common setup I see among folks just starting out or running a side hustle alongside a day job. The work mix is maybe 70% wood and acrylic, 20% paper/cardboard, and 10% whatever walks through the door.
Recommended config: Base xTool S1 with the 20W laser module.
I recommended this to a client back in March 2024. He was making custom cake toppers and small signage for local events. His typical order was 10-30 pieces with a 3-day turnaround. The 20W module cut 3mm birch plywood in one pass at a speed that kept his throughput decent without overbuying power he'd never use.
The base S1 with the 20W module runs about $1,200-1,400 depending on if you catch a sale. (Not quoting exact prices because they change, but that's the ballpark.) For that, you get:
- Enough power for most hobby-grade materials
- Good cut quality on thin materials
- Lower entry cost so you're not gambling a huge investment
Here's the trade-off though (and I wish more reviews mentioned this): the 20W module will struggle on thicker acrylic — anything above 5mm — and it's slow on dark materials that don't absorb the blue diode wavelength well. My client learned this the hard way when he took a rush order for 6mm clear acrylic trophies. Normal lead time was 4 days; he had 36 hours. The 20W barely scratched the surface in a single pass. He ended up outsourcing that job and eating the markup.
Scenario B: The Production-Run Shop
If your work is mostly production runs — same product, multiple units, repeat orders — then time is literally money. Every extra pass is lost margin.
Recommended config: xTool S1 with the 40W laser module.
I set this up for a small business that makes custom leather goods — wallets, keychains, journal covers. They were doing about 200 units a month and scaling. Their old machine (a lower-powered diode unit) needed 3-4 passes on 3oz leather. The 40W module cut that to one pass. Over a 200-unit run, that's literally hours of saved time.
The 40W module is also what I'd recommend if you're cutting thicker acrylic (up to about 10mm) or want to etch glass and coated metal at reasonable speeds. The extra power gives you headroom.
Now, the honest downsides:
- The 40W module costs roughly double the 20W — about $700-800 more depending on bundles
- It runs hotter, so you'll want to keep the S1's vent system clear (learned that after one clogged workflow)
- You don't need it if most of your work is thin materials
People assume more power is always better. Actually, more power is better if you use it. Otherwise, it's just extra cost and heat load for no gain.
Scenario C: The Mixed-Material Shop
This is the trickiest scenario because you do a bit of everything — wood, acrylic, leather, maybe some fabric cutting, maybe the occasional metal etching job with marking spray.
Recommended config: Start with the 20W S1, and add the 40W module later if volume justifies it. Or go straight to the 40W if you have the budget and floor space.
I wish I had a more satisfying answer here, but this is genuinely a "depends" situation. I'll tell you what I told a client last quarter: buy the 20W setup first. Run it for 60-90 days. Look at your job log — how many pieces did you have to re-run or outsource because of power limitations? If the number is significant, upgrade.
That's not a sales tactic; it's risk management. I've seen shops buy a 40W module and never push it past 60% power because their material mix didn't demand it.
Don't Forget the Rotary Tool and Roller Cutter
Since you're looking at the S1, you've probably seen references to the rotary tool for cylindrical items (glasses, bottles, cylindrical wood) and the roller cutter for fabric materials.
Quick note from experience: the rotary tool is surprisingly useful for small batch custom drinkware. We did a run of 100 travel mugs last holiday season — the rotary attachment paid for itself in that single order. The roller cutter for fabric, though... I'd only recommend it if fabric is a significant part of your material mix (maybe 30%+). Otherwise, cutting fabric manually or with a dedicated machine might be more practical.
How to Figure Out Which Scenario You're In
Here's a simple checklist I use:
- List your top 3 materials — if they're all under 5mm, the 20W is probably enough
- Estimate weekly volume — if you're doing 50+ pieces/week, the speed upgrade of the 40W starts making financial sense
- Check your deadlines — if you regularly have 24-48 hour turnarounds, the extra passes of a lower-power module are a liability
- Be honest about budget — if $1,200 is already stretching it, buying the 40W module and not using it is expensive dust collection
The S1 is a genuinely solid platform. I've used it enough to trust its build quality and software. The real question is matching the module to your work pattern — and that's something only you (or your job log) can answer.
If you're still unsure, start with the 20W. It's the lower-stakes option, and the modular design means you can upgrade later without replacing the entire machine. I've recommended that path to seven shops this year; five of them are still on the 20W and perfectly happy.
