The operating costs of a laser cutter are a topic that cannot be reduced solely to the laser source’s power consumption. In practice, the entire process affects the cost of laser cutting: cutting time, gas type, energy consumption by the machine, the laser source, the cooler, the exhaust fan, and the compressor, process gas consumption, material type, steel plate thickness, the quality of the CNC program, and work organization.
That is why, when choosing a fiber laser cutting machine, it is important to consider not only the purchase price, but above all the actual cost of producing a part—it is the unit cost that determines whether a given configuration will be cost-effective in day-to-day production. At STIGAL, we calculate operating costs and cutting costs based on specific parameters: material type, steel plate thickness, technology, operating time, energy consumption, and gas consumption—rather than relying solely on catalog data.
The cost of laser cutting depends on the entire workstation
A fiber laser cutter does not operate as a single, isolated component—it is a complete processing station in which several systems draw power simultaneously. In addition to the machine itself and the laser source, the system also includes a cooler, an exhaust fan, a filtration system, a compressor, and other auxiliary components, depending on the configuration.
Therefore, the actual operating cost should take into account the power consumption of the entire system, not just the laser source. A higher-power laser may consume more energy, but it also cuts faster, reduces part production time, and increases productivity. In practice, then, what matters is not only how much energy the machine consumes per hour, but also how many parts it produces during that time—it is this relationship that has the greatest impact on the unit cost.
| Workstation Component | Impact on operating costs |
|---|---|
| CNC Machine | It powers the drives, control system, and working axes that perform the cutting process |
| Laser source | Generates a beam; power consumption depends on the power, cutting parameters, and material |
| Laser Cooler | Maintains stable operating conditions for the source and the head—constant power consumption |
| Exhaust Fan and Filtration | Removes smoke and dust generated during cutting |
| Compressor | Powers auxiliary systems or compressed-air cutting (AirCut) |
| Process gas | Oxygen or nitrogen — cost depends on cutting thickness, pressure, and cutting time |
Cutting time — one of the most important cost factors
Cutting time has a direct impact on operating costs. The longer the process takes, the longer the machine, laser source, cooler, exhaust fan, and compressor operate—and the more process gas is consumed. However, cutting time is influenced not only by the length of the contour, but also by the number of pierces, the workpiece geometry, material thickness, gas type, process parameters, cutting sequence, and the quality of the CNC program.
A part with many holes, short sections, and a large number of cutouts can be more time-consuming to process than a larger part with simpler geometry. Therefore, it is best to analyze the cost of laser cutting based on an actual part or a typical production batch—only the cutting time for a specific part reveals how the machine will perform under real-world conditions.
Current consumption by the machine and auxiliary systems
The cost analysis must take into account the power consumption of all key components of the workstation: the laser cutter, the laser source, the cooler, the exhaust fan, and the compressor. A CNC machine consumes energy for its drives, CNC control, and working axes, while the laser source consumes energy to generate the beam—its power consumption depends on the laser power, cutting parameters, and material type.
A laser cooler is essential for maintaining stable operating conditions for the laser source and the laser head, while the exhaust fan and filtration system are responsible for removing fumes and dust. The compressor can be a significant cost factor, especially when it powers auxiliary systems or prepares the process medium. For this reason, the actual energy cost is that of the entire system, not just the laser itself.
Cost of process gas — oxygen and nitrogen
The second very important cost factor is process gas. Depending on the material, thickness, and desired result, various technologies are used—including oxygen cutting and nitrogen cutting.
Oxy-fuel cutting is commonly used for carbon steel—for thin and medium-thickness steel plates as well as for very thick sections; the thickest sections (e.g., over 20 mm) typically require more powerful power sources, in the range of 30 kW. Oxygen aids in the combustion of the material, which enables efficient cutting of thick sections; the cost depends mainly on cutting time, oxygen consumption, and process parameters. Nitrogen cutting is used where a clean, non-oxidized edge is essential—for stainless steel, aluminium, and parts intended for further machining, welding, painting, or assembly. Nitrogen also allows for fast cutting, which is important in mass production, but at greater thicknesses and higher operating pressures, it can be a significant cost factor.
An alternative could be compressed-air cutting (AirCut). In many cases, nitrogen can be replaced with a one-time investment in a compressor, allowing for cutting with compressed air while maintaining a comparable process speed—which significantly reduces operating costs. Thanks to this technology, one of our customers saves approximately 30,000 PLN per month. However, it’s important to remember to include the energy consumed by the compressor in the total cost, which can be calculated precisely.
Laser Source Power vs. Actual Production Cost
The power of the laser source is crucial to productivity, but it should not be evaluated solely in terms of cost. Higher power means greater energy consumption, but it also allows for faster cutting, shorter piercing times, and the production of more parts per shift. In mass production, a more powerful laser can actually lower the unit cost, even if the entire workstation consumes more energy—what matters most is the relationship between power consumption, cutting time, and the number of finished parts.
Therefore, the selection of power should be based on actual production needs: the type of material, the range of thicknesses, the expected productivity, typical workpieces, and the planned machine load. We discuss this topic in more detail in our guide on how to select the power of a fiber laser.
Material, steel plate thickness, and part geometry
The cost of cutting also depends on the material—cutting carbon steel, stainless steel, aluminium, or other metals involves different processes. The thickness of the steel plate, surface quality, flatness of the plate, protective coatings, and consistency of supply are also important factors. Thicker material usually requires a longer piercing time, the right gas, and stable parameters, while material that is more difficult to process can increase cutting time.
The geometry of the part has a significant impact. Parts with a large number of holes, small contours, and frequent perforations incur higher costs than simple parts with long, smooth cutting lines. Therefore, cost should not be assessed solely on the basis of material surface area or steel plate thickness.
CNC Program and Sheet Utilization
The cost of cutting is influenced by the quality of the CNC program. A well-prepared program shortens processing time, reduces idle passes, lowers gas consumption, and improves utilization of the material. Nesting—the arrangement of parts on a sheet—is of key importance: better utilization of the steel plate means less scrap, and less scrap means lower production costs, which is particularly important for expensive materials and large production runs.
CAD/CAM software, the technician’s expertise, and proper job preparation can have just as much of an impact on the unit cost as the machine’s configuration itself. Even a high-performance laser cutter won’t reach its full potential if the process isn’t properly prepared.
Cutting Costs and Further Processing of the Workpiece
The actual cost of production does not end when the cutting process is complete. If a part requires deburring, cleaning, edge finishing, or weld preparation and painting, these steps must also be factored into the total cost. Well-chosen laser cutting technology often reduces the need for further processing—a clean and consistent edge shortens the time needed to prepare the part for subsequent stages, such as bending, welding, assembly, or painting. Our product lineup includes, among other things, compact laser cutters for steel plates tailored to specific production profiles.
Why is it worth calculating the costs for a specific production run?
Every facility operates differently—materials, thicknesses, part geometries, batch sizes, quality requirements, and work organization all vary. Therefore, the operating costs of a laser cutter should be calculated on a case-by-case basis. At STIGAL, we calculate cutting costs based on actual data: cutting time, power consumption by the machine and auxiliary components (laser source, cooler, exhaust fan, compressor), and the cost of gas.
This approach allows you to assess how a given fiber laser cutter will perform in a specific facility—not only in terms of its capabilities, but also how its configuration affects the cost per part, productivity, and return on investment. The selection of a machine is then based not on a single parameter, but on how well it fits real-world production conditions. If you’re also considering other technologies, a guide on laser or plasma cutting—how to choose the right cutting technology—can be helpful.
Would you like to know the actual operating costs of a laser cutter at your facility?
We will calculate the cutting costs for specific production parameters—material, cutting thickness, technology, labor hours, energy consumption, and gas consumption—and help you choose a solution tailored to your production needs.
Frequently Asked Questions — Operating Costs of a Laser Cutter
Costs are influenced by cutting time, the machine’s power consumption, the laser source, the cooler, the exhaust fan, and the compressor; the cost of process gas; the type of material; steel plate thickness; workpiece geometry; the CNC program; nesting; operator labor, and any subsequent machining.
No. The power of the laser source is important, but it does not reflect the full operating costs of the workstation. You must also take into account the power consumption of the machine, the chiller, the exhaust system, the compressor, and other auxiliary systems.
The cutting time determines how long the entire workstation operates and how long the process gas is consumed. The shorter the time required to produce a part, the higher the machine's productivity and the greater the chance of a lower unit cost.
Yes. In many cases, nitrogen can be replaced with compressed-air cutting (AirCut) after a one-time investment in a compressor, while maintaining a comparable process speed. However, the energy consumed by the compressor must be factored into the cost. For one of our customers, this implementation results in savings of approximately 30,000 PLN per month.
Yes. STIGAL calculates cutting costs based on specific production data—cutting time, material, thickness, technology (oxygen or nitrogen cutting), power consumption of the workstation, and the cost of gas. This allows the customer to better assess the cost-effectiveness of a given machine configuration.
