Why I Wrote This Comparison (and Why You Should Care)
I manage purchasing for a mid-sized fabrication workshop—roughly $180K annually across 12 vendors. When I took over in 2022, I quickly learned that buying the latest gadget from xTool (or any brand) isn't the same as buying the right tool. This comparison covers the xTool D1 Pro 10W, the S1 diode laser, the P2 CO₂ laser, the F2 welder, and the Metalfab plasma cutter—plus the confusing “CO₂ laser how many treatments” search that kept coming up in our internal queries.
I'm not a sales rep. I'm the person who has to justify every PO to finance. So here's what I wish I'd known before spending our budget.
The Comparison Framework: What Matters for a Small Shop
Instead of listing specs, I'm comparing across three real-world dimensions:
- Upfront cost vs. total cost (including accessories, legs/exhaust, and consumables)
- Ease of integration (How many vendors do you need to make it work?)
- Scalability for small orders (Can you justify the investment if you're cutting 50 parts a week?)
Let's dive into each dimension head-to-head.
Dimension 1: Upfront Cost vs. Total Cost of Ownership
xTool D1 Pro 10W ($399 as of March 2025)
Cheapest entry point. But factor in the rotary attachment ($149) and an enclosure ($129) if you're cutting anything smelly. Total: ~$677. Still affordable—and you can grow into it.
xTool S1 (40W diode, ~$1,099)
Includes an enclosure. No rotary needed for basic cylinders. Total out-the-door: ~$1,200. Small shop buyers often miss the hidden cost—Air Assist ($99) if you buy the base kit. I did. (Note to self: always read the “what's in the box” line twice.)
xTool P2 CO₂ laser (55W, ~$4,499)
The CO₂ laser legs (the height-adjustable stand) add $199. Exhaust kit? Another $149. Total with essential accessories: ~$4,847. That's a big jump for a small shop. But for cutting acrylic in bulk? Worth it.
xTool F2 welder (fiber laser, ~$3,999)
Cost per weld is low—no filler rod, no gas bottles. But the learning curve cost? Steep. My first welds looked like a robot having a seizure. Expect scrap material costs of $50–$100 while you learn.
xTool Metalfab plasma cutter (Cut50, ~$2,799)
Consumables (nozzles, electrodes) run about $30 every 200 cuts. That's lower than most industrial plasma units. But: it needs compressed air. If your shop doesn't have a compressor, add $400–$600.
Quick take: Small orders (<10 units) often cost more per piece with a plasma or CO₂ laser because of setup waste. The D1 Pro wins for prototyping. The Metalfab wins if you need steel parts at scale.
Dimension 2: Ease of Integration—Plug & Play vs. Patchwork
xTool D1 Pro / S1
Software: XCS (free, works with Lightburn). Materials: tested preset profiles for basswood, leather, acrylic. Truly plug-and-play for a single operator. No multi-vendor hassle.
xTool P2 CO₂ laser
Heavier machine (77 lbs). The CO₂ laser legs are nice—but you'll need a dedicated table or the official stand. Exhaust venting means you can't just plop it in a corner. In our 2024 workshop expansion, I had to coordinate the P2 install with an HVAC contractor. That added $400 in labor. Miscommunication: I said “standard exhaust port.” The contractor heard “4-inch dryer vent.” Result: a costly resize. (Communication failure—I now send exact measurements in writing.)
xTool F2 welder
Fiber laser—no gas, no filler. But you need eye protection (laser safety glasses, ~$50) and a fume extractor ($200+). The F2 itself is compact, but the ecosystem around it (jigs, clamps) adds vendor count. For a small shop used to one-stop shopping, that's friction.
xTool Metalfab plasma cutter
Requires compressed air (7–8 CFM at 90 PSI). Also needs a 220V outlet (or a converter). If your shop already has that, great. If not, you're now buying from three vendors: xTool, an air compressor supplier, and an electrician.
Integration winner for small shops: D1 Pro. One box, one manufacturer, one software. The Metalfab and P2 need more infrastructure—fine for established shops, risky for startups.
Dimension 3: Small-Order Friendliness (The “Small Customer” Test)
When I started in 2020, I made the classic mistake: I bought a big CO₂ laser (brand not relevant) because “you'll grow into it.” I didn't. I was stuck with a machine that was overkill for 10-keychain orders.
xTool D1 Pro 10W
Perfect for small runs. Cost per piece for a custom coaster? ~$0.30 including material waste. Minimum order size? One coaster. That's small-friendly.
xTool S1
Faster than the D1 Pro—can do 20 coasters in the time the D1 does 10. But the material cost for a small scrap piece is similar. For orders under 50 units, the S1 works—but the D1 Pro is more forgiving for a beginner.
xTool P2 CO₂ laser
The sweet spot is 50–500 acrylic parts. For 10 parts, the setup time alone (installing the CO₂ laser legs, aligning optics, removing the honeycomb) makes it inefficient. Total cost per small run is higher than using a diode laser.
xTool F2 welder
Small welds (like jewelry or brackets) are fast. But the laser spot is so small that you need precise fixturing. For a one-off repair, it's overkill. For 20 identical welds, it's brilliant.
xTool Metalfab plasma cutter
Small metal parts (under 12 inches) can be cut, but the kerf (cut width) is wider than laser. For precision small parts, a fiber laser is better. For structural brackets? Plasma wins.
After 5 years of managing tool purchases, I've come to believe that “small-friendly” isn't just about price—it's about setup time, waste per job, and how easy it is to say “let's just try one.” The D1 Pro and F2 are the most try-friendly. The Metalfab and P2 reward volume.
Bonus: The “CO₂ Laser How Many Treatments” Confusion
I saw this keyword and had to address it. If you're searching for “CO₂ laser how many treatments,” you're probably asking about medical CO₂ laser skin treatments, not the P2. They are completely different. Medical CO₂ lasers typically need 3–5 sessions for results. The xTool P2 is for engraving and cutting materials, not skin. If you need a CO₂ laser for medical use, consult a dermatologist—not a fabrication supplier. But if you meant “how many passes for acrylic,” the answer is 1 pass at 10mm/s for 3mm acrylic on the P2.
When to Buy Each—Scenarios for Small Shops
- Buy the D1 Pro 10W if: You're a hobbyist, prototyper, or have orders under 50 units. Budget: under $700 total. You don't want to fuss with CO₂ laser legs or exhaust.
- Buy the S1 if: You need more power than D1 but can't afford CO₂. One-box solution, no assembly. Good for small business branding (custom acrylic signs).
- Buy the P2 CO₂ laser if: You cut acrylic, wood, or leather in volumes of 50+ per job. You can budget for the CO₂ laser legs, exhaust, and installation labor ($4,800+). Not small-friendly, but efficient for growth.
- Buy the F2 welder if: You need precise, small welds in stainless or titanium—and you're okay with a steeper learning curve. Best for small-midsize repair shops or jewelry makers.
- Buy the Metalfab plasma cutter if: You cut metal parts regularly (50+ per week) and already have compressed air and 220V. The Cut50 unit itself is affordable for what it does, but infrastructure costs add up.
In my department, we run a D1 Pro for rapid prototyping and a Metalfab for customer metal parts. The P2 sits idle during slow weeks—useful, but not essential for every order. That's the honest truth.
Pricing as of March 2025. Verify current costs at xTool.com or authorized resellers. I'm not an xTool employee; I'm just a buyer who prefers real-world comparisons over spec sheets.
