Is Laser Cutting More Expensive Than CNC?

Stop guessing, the wrong choice may cause the cost to soar by 50%!

As an engineer or purchaser, when you see two process quotations that differ by nearly 50%, you must be familiar with the anxiety of out-of-control costs. This kind of horror often stems from a fundamental misunderstanding: the arbitrary belief that “laser cutting is always cheap” or “CNC must be expensive.”

The truth is: “Is laser cutting more expensive than CNC?” is a false proposition in itself. The answer depends entirely on the specific details of your project:

Material and thickness: Laser is good at thin plates, and CNC can handle thicker and harder materials.

Shape complexity: Laser is good at 2D contour cutting, and CNC can complete complex 3D milling.

Accuracy and tolerance: CNC usually provides higher accuracy.

Surface treatment requirements: CNC can be done in one step, and laser parts often require secondary processing.

Batch size: Small batch laser is fast and economical, and large batch CNC may have more economies of scale.

Choosing the wrong process costs far more than you think – not only money, but also time and project risks. Understanding the core differences and applicable scenarios of the two is the key to proactively optimizing costs and controlling manufacturing decisions. There is no absolute “expensive” or “cheap”, only “more suitable” or “less suitable” for your project.

Laser Cutting VS. CNC Machining: A Quick Selection Guide

This guide will give you an in-depth understanding of the essential differences between the two technologies, analyze the core variables that affect the final laser cutting price and CNC price, and through a real case, let you clearly see how we choose the best solution for our customers.

Here’s What You’ll Learn:

1. A clear cost comparison framework: Understand the core working principle differences between laser and CNC, and why this determines their “cost sweet spot”.
2. 3 key factors that determine cost: How your material type and thickness, design dimensions (2D vs. 3D), and precision requirements point directly to the more economical option.
3. Beyond “either/or”: When should you consider water jet or plasma cutting as a better solution? Professional answers for specific materials.
4. Real-life examples from our workshop: The cost evolution of a custom aluminum panel clearly shows how design changes overturn the conclusion of “who is cheaper”.
5. Enterprise decision-making guide: “Buy a machine or find a service?” Make the most efficient investment or outsourcing choice based on core product needs.
6. Authoritative answers to common cost myths (FAQ): Thoroughly clarify key questions such as “Laser must be cheap?” and “Is CNC low-cost to run?”.

Now, let’s clear the cost fog and find the most economical manufacturing path for your project.

Why Trust Our Analysis? We Have Both The Beam And The Tool

In the shop where I work every day, you will see a very interesting scene: high-powered laser cutting machines and high-precision CNC machining centers, standing side by side, busy. Next to the sparks of laser cutting, there may be a scene where a precision milling cutter steadily cuts on metal.

This is why I say that at LS, we are not standing for a certain technology. We are experts in custom laser cutting manufacturing and experts in CNC machining. What does this mean? It means that when your part drawings are placed on my desk, I will never think about “laser or CNC”, but “which technology can complete this task most efficiently, perfectly and economically?”.

I have no bias and will not force a certain technology. Laser cutting is fast, has low heat impact, and is suitable for complex 2D contours? Then use it. CNC machining can handle thicker materials, achieve fine 3D features and tight tolerances? Then it is the first choice. Sometimes, the same part even requires a combination of two technologies.

Our goal is very simple: to find the most efficient and economical way to process your specific part. This advice is not theoretical, but based on the experience I – and our entire engineering team – have accumulated in thousands of real projects. We have seen firsthand what saves time, what reduces costs, and what ensures the highest quality.

So when you ask us at LS for a quote, you are not just getting a sales pitch, but an engineering solution based on practical, disassembled technical details. We will use the two most powerful tools in our workshop – beams and cutters – and the experience of hundreds of projects we have personally participated in to find the best solution for you.

The Essential Difference: Focused Beam VS. Spinning Tool

“To understand the cost difference, you first have to understand how they work.”

Quick reference table of the essential differences between laser cutting and CNC machining

1. Laser cutting: light energy is converted into heat energy (non-contact thermal processing)

(1) Core principle:

Use highly focused high-energy laser beam (usually forming a light spot with a very small diameter on the surface of the material).

The laser energy is absorbed by the material, instantly generating extremely high temperatures, causing the material to partially melt, burn or directly vaporize.

Auxiliary gas (such as oxygen, nitrogen, air) is ejected coaxially along the beam. Its main functions are:

Blow away the molten or vaporized material (slag) to form a clean cut.

Participate in chemical reactions in certain materials (such as oxygen-assisted combustion cutting of steel).

Protect optical lenses.

(2) Essential characteristics:

Non-contact (the tool does not touch the material), thermal processing (removing materials by heat).

(3) Core advantages:

Fast speed: Especially when cutting thin plates, the speed is much faster than mechanical processing.

Narrow slit: The laser beam is very thin, with little material loss, suitable for fine contours.

Small heat-affected zone: Although heat is involved, the high energy concentration and rapid passage make the thermal impact on the surrounding area of ​​the material relatively small (especially when using protective gases such as nitrogen).

Complex two-dimensional patterns: Computer-controlled beam path can cut arbitrarily complex plane patterns extremely efficiently and accurately.

No tool wear: The “tool” is the laser beam itself, and there is no physical wear problem (but the optical lens needs maintenance).

(4) Key limitations:

Mainly limited to two-dimensional cutting/punching: It is difficult to process complex three-dimensional shapes (although 3D/five-axis laser cutting exists, its application is far less extensive than 2D).

Material thickness limitation: Cutting ability decreases sharply with increasing material thickness, and the cut quality (verticality, roughness) may deteriorate.

Material limitations:

Cannot effectively cut highly reflective materials (such as pure copper, brass, and aluminum are sometimes difficult) and highly thermally conductive materials (heat dissipation is too fast).

Some materials (such as PVC) will produce toxic gases during laser cutting.

Heat-sensitive materials (such as some plastics) may deform, burn or produce harmful fumes due to high temperatures.

High energy consumption: The laser generator itself consumes a lot of power.

2. CNC milling: mechanical material removal (contact machining)

(1) Core principle:

Use physical hard tools (milling cutters, drills, taps, etc.) that rotate at high speeds and are precisely controlled by a computer program (G code).

The cutting edge of the tool mechanically squeezes, shears, and scrapes the material, removing it from the workpiece body to form chips.

Coolant (cutting fluid) is usually required to lubricate and cool the tool and workpiece, and to flush away the chips.

(2) Essential characteristics:

Contact (the tool is in physical contact with the material), machining/subtractive manufacturing (shape is obtained by removing material).

(3) Core advantages:

High precision and surface quality: It can achieve extremely high dimensional accuracy and excellent surface finish (low Ra value).

Complex 3D geometry: It is good at manufacturing 3D parts (3-axis, 4-axis, 5-axis) with complex surfaces, cavities, bosses, threads and other features.

Wide range of material adaptability: Almost any sufficiently hard material (metal, plastic, wood, composite material, stone, etc.) can be processed as long as the matching tool and parameters are selected. Insensitive to the optical or thermal properties of the material (reflectivity, thermal conductivity).

Versatility: A CNC milling machine (machining center) can perform a variety of operations: milling planes/contours, drilling, boring, tapping, reaming, engraving, etc.

Processing thick workpieces: Not fundamentally limited by material thickness (as long as the machine tool stroke allows), deep cavity and large depth processing can be performed.

(4) Key limitations:

Relatively slow: The material removal speed is usually slower than laser cutting of thin plates (especially when processing complex 3D shapes).

Tool wear and cost: Tools are consumables and will wear or even break. They need to be replaced regularly, which brings additional costs.

Cutting force and clamping: Mechanical contact generates cutting force, and the workpiece needs to be firmly clamped to avoid vibration and displacement. Thin-walled or flexible parts may be deformed.

Geometric limitations: Tool size and shape will limit the internal sharp corners (minimum corner radius) and deep narrow grooves that can be processed.

Kerf width and material waste: The tool diameter determines the minimum kerf width, which is usually wider than the laser kerf, and the material utilization rate may be slightly lower (especially when contouring).

Laser cutting: It has an overwhelming advantage in high-speed, fine two-dimensional cutting of thin plate materials, and is a typical representative of non-contact, thermal processes.
CNC milling: It is irreplaceable in manufacturing high-precision, complex three-dimensional geometries, processing thick or extensive materials, and is the core strength of contact, mechanical processing.

Cost Showdown Round 1: Material VS. Thickness

“The bill of materials directly points to the more economical option – this is the most important factor in determining cost.”

The cost efficiency of laser cutting and CNC machining is highly dependent on the material type and workpiece thickness. The following table quickly reveals the core battlefield:

Laser cutting’s “sweet spot”: the absolute home of thin, soft, non-metallic materials

When your design involves the following materials, laser cutting is the most cost-effective solution:

Thin metal plates (0.5mm – 10mm): Laser has a crushing speed advantage in the field of thin plates. For example, when cutting 1mm stainless steel, the laser speed can reach 5-10 times that of CNC milling, and the unit cost is greatly reduced.

Acrylic, wood, plywood: The laser beam instantly vaporizes the material, and the edge automatically melts and smoothes (wood can produce a designed charring effect), eliminating the secondary grinding required by CNC.

Paper, fabric, leather: Non-contact cutting avoids material deformation, and complex patterns can also be completed at high speed – this is an area that CNC physical tools cannot reach.

Key cost tips: Within the “sweet spot” thickness, the high speed + low energy consumption + no tool loss of the laser makes its unit cost usually 30%-50% lower than that of CNC.

The “fortress” of CNC machining: conquering heavy, refractory and heat-sensitive materials

When you face the following challenges, CNC machining is a more economical and reliable choice:

Thick metal blocks (>20mm): The efficiency of laser cutting thick metals drops drastically (energy is absorbed in large quantities), while CNC milling cutters can cut continuously and stably, reversing the time and energy cost advantages.

Engineering plastics (POM, PEEK, nylon, etc.): The high temperature of the laser can easily cause the material to melt and carbonize, and the edge quality is out of control. CNC’s physical cutting maintains the integrity of the material and has higher precision.

Aluminum blocks: Although lasers can cut aluminum, high reflectivity requires special parameters and speed is limited. CNC’s processing efficiency and flexibility for aluminum (milling, drilling, and tapping in one) are more cost-effective.

Heat-sensitive warning: Trying to cut materials such as POM with a laser? There is a high probability of getting deformed, yellowed, and sticky scraps – the rework cost is far higher than directly choosing CNC.

Cost is locked by your bill of materials

“Material and thickness” is the first watershed of manufacturing cost:

Choose laser: If your part is thin metal (≤10mm) or organic material/fabric, laser will significantly reduce costs.

Choose CNC: If it involves thick metal blocks (>20mm) or engineering plastics/aluminum blocks, CNC is a more cost-effective solution.

Cost Showdown Round 2: The Tradeoff between Design Complexity And Precision

Your design drawings themselves hide the secret of cost.The geometric complexity and precision requirements of the design directly determine the cost difference between laser cutting and CNC processing.

When laser is called for in design: the cost saver section of fine two-dimensional and sharp angles

Design features that will save money significantly by choosing laser cutting:

Fine two-dimensional patterns (e.g., metal lace/heat sink grille):
The laser “draws” fine contours at lightning speed, and time to cut 100 holes ≈ time to CNC machine 1 hole. The time cost savings can be up to 10 times.

Sharp inner angle (90°):
Laser beam diameter = 0.05-0.2mm, that can easily form right angles out of reach of the tip of the tool without corner cleaning process (time-consuming and cost-increasing 30%+).

Micro structures (<1mm line width/aperture):
The laser does not entail physical touch and can cut finer structures than the smallest CNC tool (usually ≥1mm).

Cost code: But when the design has high-density hole arrays + sharp angles, choosing laser will maximize CNC path planning time + tool switch loss, and the total cost is reduced by 40%+.

When the design requires CNC: 3D solid and high-precision fortress

The following features make CNC more economical:

Any 3D feature (bevel/curved surface/step):
Laser only cuts vertical planes, whereas CNC cuts three-dimensional structures through 3-axis/5-axis linkage. Stacking 3D with multi-layer lasers? Labor cost will negate all advantages.

Functional threaded holes (M3 and larger):
CNC can drill + tap (or thread mill) in one step, while laser needs secondary processing for hole opening – the latter will add 50% additional cost and compromised thread strength.

Ultra-high precision requirements (within ±0.05mm):
CNC mechanical rigidity + closed-loop control system can be micron-level accurate, and thermal deformation of lasers is extremely costly in the precision sector.

Accuracy trap example:
Aluminum alloy positioning pieces of ±0.03mm tolerance, if laser cutting is forced:

Heat-affected zone leads to dimensional drift of ±0.1mm → 100% scrap rate

Although the processing unit cost is 20% higher, the yield is 95% → the actual cost is saved 37%

Maintain process costs in design language

The drawing lines are the cost source code:

Laser design optimization: focus on two-dimensional plane + complex hollowing + sharp angles, and take full advantage of the cost-saving wizardry of “light pen draw shape”.

Design and planning of CNC: apply three-dimensional solid + thread + ultra-precision tolerance, and fully realize the irreplaceable advantage of mechanical cutting.

Beyond The Two: When Should You Consider Waterjet Or Plasma Cutting?

While laser cutting and CNC machining dominate the mainstream, smart manufacturers know they need variety in their toolbox. Waterjet and plasma cuttingare powerful answers to specific manufacturing challenges. When should you consider them? The following table provides a quick guide:

Case Study In Practice: The Method Of Cost Optimization Of A Customized Panel

Project background:

We recently assisted an electrical devices manufacturer in engraving 500 aluminum front panels to a size of 200x150mm for its new product. This is an example generic cost-saving case from design to manufacturing, demonstrating the influence design details can have on the choice of processing technology and final cost.

Version A: Plain panel design

Design features: 3mm thick aluminium plate, featuring round mounting holes and square screen openings (clean 2D features).

LS cost analysis review:

Solution 1: Laser cutting: Simple and efficient, and costs approximately $8 per piece.

Solution 2: CNC machining: It has programming and clamping, and it’s approximately $15 per piece.

LS conclusion and solution: Laser cutting has an runaway cost and efficiency lead, which saves the client $3,500 overall. We were able to make and execute the laser cutting solution successfully.

Version B: Design improvement includes 3D functionality

Design changes: Chamfer on panel edge, milling of grooves on back (for insertion of a seal).

LS cost analysis reconsideration:

Solution 1: Laser cutting + CNC secondary machining: Two separate operations (laser cutting outline, CNC secondary processing chamfer/groove) and two clamps are required, and the unit price is much greater at approximately $22.

Solution 2: Pure CNC machining: All features (contour, hole, chamfer, groove) are finished in single clamping, and unit cost is roughly $18.

LS conclusion and solution: Since the extra chamfers and grooves (3D features) make the laser cutting solution more complex and expensive, the simple CNC machining solution has now been an affordable (lower cost) and more effective (less turnover) option with the advantage of completing all processes in one clamping. We therefore shifted the processing strategy accordingly.

LS experience summary

This case clearly illustrates:

Design determines cost: The feature type on the panel (2D vs 3D) is the core driving factor for selecting the optimal processing technology. Under the basic 2D features, laser cutting has a significant advantage; after introducing 3D features such as chamfers and grooves, the comprehensive benefits of CNC machining are reversed.

The value of process integration: In version B, the pure CNC solution completes all processing in a single clamping, avoiding the extra time, labor and potential error costs caused by secondary clamping, which is the key to cost optimization.

The importance of early communication: Considering the feasibility and cost impact of the processing technology (DFM) in the product design stage helps to achieve the optimal manufacturing cost. We at LS are very happy to provide such early design consultation to our customers.

FAQ – Final Questions About Cost

1. So, is CNC cheaper than laser cutting?

The final conclusion is not absolute; the cost of CNC and laser cutting depends on the material type, thickness, quantity and design complexity. For thick metals (such as steel over 10mm) or large-scale production, CNC machining may be more economical because it excels at heavy-duty cutting; while for thin plates (such as 1-5mm aluminum or stainless steel), complex shapes or small batches, laser cutting is generally faster, more accurate and has a lower unit cost. Therefore, there is no one-size-fits-all cheap solution. It is recommended to conduct a cost simulation based on your specific project parameters (such as material specifications and output) or consult a supplier to obtain a personalized comparison.

2. Is the laser cutting machine expensive to operate?

The operating cost of a laser cutting machine varies depending on the type of equipment, frequency of use and scale, and mainly includes power consumption (high-power lasers consume a lot of power), auxiliary gases (such as oxygen or nitrogen for different materials), replacement of consumable parts (such as lenses and nozzles), regular maintenance, and operator fees. The initial investment is high, but the unit cost can be significantly reduced through mass production and efficient operation; conversely, small-scale or intermittent use may result in higher operating costs. Overall, it is not necessarily “expensive”, but you need to evaluate your production needs: high cost-effectiveness at high utilization, and low production may be uneconomical.

3. How can I get the most accurate quote for my project?

To get the most accurate quote, please prepare detailed project specifications: including material type and thickness, part size, quantity, tolerance requirements, surface treatment requirements, and CAD drawings (such as DXF files). Then contact multiple professional suppliers (such as local processing plants or online platforms such as LS), provide complete information and inquire, and clarify all potential costs such as setup fees, material costs, and logistics costs. When comparing responses, verify hidden items and consider requesting sample testing; use quotation tools or industry consultants to verify data to ensure transparency and comprehensiveness, thereby optimizing cost estimates.

Conclusion

Laser cutting and CNC machining are not mutually exclusive. They are essentially the best solutions for different machining needs. The key to effectively controlling manufacturing costs lies in a deep understanding of the core differences between the two processes (such as applicable materials, machining thickness, geometric complexity, etc.), and accurately choosing according to the specific requirements of your design.

The wrong process selection is often costly – seemingly “cheap” solutions may ultimately lead to higher total costs.

No need to worry about process selection. Leave professional matters to professionals: upload your CAD files to LS’s secure platform immediately. Our team of engineers will conduct a detailed “manufacturability analysis” (DFM) for you, accurately evaluate your design, and provide a competitive quote based on the optimal machining process.

Experience the ease and efficiency of professional decision-making – let LS experts optimize your manufacturing path for you.

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