Why Users Are Replacing Laser Engravers in 2025

Is your laser engraver holding you back from bigger and better projects? You're not alone.

Many creators are upgrading in 2025, not because their machines are broken, but because they've outgrown their capabilities. 

We analyzed why users are replacing their old models—and what they're looking for next.

Power Needs Drive 30% of Replacements

To pinpoint the real reasons users are replacing their laser engravers—and not just because they're broken—we conducted a deep dive into online communities.

We scoured about 100 threads across Reddit (r/lasercutting, r/Laserengraving), maker forums (LightBurn, CNCZone, SawmillCreek), and user reviews.

These reasons can be grouped into seven major categories that have come to light.

1. Insufficient Power

• Old diode machines (2.5–10 W) can't cut thicker materials (e.g., >5 mm acrylic, hardwood).
• CO₂ tubes degrade over time (a 40 W may drop to ~30 W after 2–3 years).

Many users replace when the machine simply can't handle desired materials anymore.

2. Outdated Software / Controller

• Legacy boards tied to clunky, XP-only drivers (e.g., M2Nano).
• Lack of LightBurn support is a dealbreaker for many.

Instead of spending $200–500 on a controller swap, they buy a new plug-and-play model.

3. Work Area Too Small

• Entry-level engravers often have 200–300 mm beds.

Growing businesses need 400×400 mm or pass-through capability: replacing is easier than frame extension.

4. Reliability & Maintenance Fatigue

• Worn belts, failing power supplies, water leaks, and failing optics = constant downtime.

Businesses especially replace machines to reduce maintenance overhead.

5. Safety & Compliance

• Older open-frame diode lasers don't meet 2025 safety standards (no enclosure, no HEPA, no flame sensor).

Schools, labs, and pros replace machines to comply with regulations.

6. New Features Too Hard to Retrofit

Modern units come with:

• Dual-laser modules (blue diode + IR)
• AI camera alignment
• Auto-focus & auto-lift bed
• Cloud/IoT integration

Hard/impossible to retrofit onto legacy machines.

7. Economics of Upgrading vs. Replacing

• A serious upgrade path (new tube + controller + cooling + exhaust) can cost 60–80% of a new machine.

Many conclude: “Why not just buy new with a warranty?”

Hardware Factors Dominate Replacement Decisions

To provide a clearer view, we categorized the reasons into hardware-oriented and software-oriented replacements. What we found is that most users replace their laser engravers due to hardware limitations.

1. Hardware-Oriented

These are driven by machine performance, physical limits, or safety hardware:

• Power limitations: 28
• Work area too small: 15
• Reliability/maintenance fatigue: 15
• Safety & compliance: 10
• New features can't retrofit: 7
• Trade-in/eco programs: 5

Subtotal: 80 / 100 users

2. Software-Oriented

These are driven by workflow, controller, and compatibility:

• Outdated software/controller: 20

(Part of reliability is tied to firmware/software instability)

Subtotal: 20 / 100 users

Should I Replace My Laser Engraver

If you're here, it's probably because you're thinking about replacing your laser engraver. Maybe you want better cutting performance or wider material support—and that's exactly what we're here to help with.

Let's take a closer look at upgrading your laser engraver. Follow these steps to find the machine that's the perfect fit for you. First, ask yourself about these questions.

1. What Materials Do You Want To Cut Or Engrave

Different types of lasers perform differently on various materials. Pick up the laser type based on your target material.

• Diode (450 nm): Organics (wood, leather), acrylic (not clear), coated metals.
• CO₂ (10,600 nm): Organics, clear acrylic, glass, but not bare metals.
• Fiber (1064 nm): Metals, some plastics, industrial use.
• UV (355 nm): Plastics, glass, electronics, medical — fine “cold marking.”
• Infrared (1064 nm add-on / 808–980 nm): Budget option for metal marking on hobby/desktop machines.

And you shouldn't use these lasers to engrave your target material:

• Diode Lasers: Worst on clear acrylic, glass, and bare metals.
• CO₂Lasers: Worst on bare metals.
• Fiber Lasers: Worst on wood, glass, and clear acrylic.
• UV Lasers: Worst on thick organics (wood, leather) and heavy cutting.
• Infrared Lasers: Worst on wood, clear acrylic, and glass.

It's a classic trade-off: if you have a machine that's great for engraving bare metal, it won't perform well on organic materials like wood. You can't have your cake and eat it too.

 That's why the latest trend is dual-laser engravers that combine a diode laser and an infrared laser, allowing you to engrave both organic materials and metal with a single machine.

2. How Much Power Do You Really Need

It depends on your projects: hobby engraving may only need 5–10W diode power, while cutting thicker wood or acrylic requires 20–40W diodes or 40–60W CO₂, and serious metal work needs 20W+ fiber.

3. Is Your Workspace Big Enough

If your projects feel cramped, you may need a larger bed (400×400 mm or more) or a pass-through slot for long boards; otherwise, a compact machine is often enough for small crafts.

4. Are You Struggling With Software Or Compatibility

Most new laser engravers should support mainstream laser design software such as LightBurn and LaserGRBL.

5. How Important Are Safety Features

If you work at home, in schools, or in a business, an enclosed machine with HEPA filters, flame detection, and auto-shutoff isn’t optional—it’s essential.

6. What’s Your Budget

From budget-friendly options:

Diode Lasers < Infrared Lasers (IR modules) < CO₂ Lasers < Fiber Lasers < UV Lasers.

When upgrading, the key is to balance cost with performance.

Brand Trends in the 2025 Desktop Laser Engraver Market

Based on official website traffic, xTool and Glowforge together account for nearly 80% of the market.

Their machines are generally more expensive than the average laser engraver, reflecting a brand premium.

Meanwhile, reliable and emerging brands such as Creality Falcon Laser, OMTech Laser, and Thunder Laser are also gaining traction.

The End

Upgrading your laser engraver is a major decision, but it's often the smartest move for serious hobbyists and growing businesses.

By prioritizing your needs—whether it's more power, a larger work area, or modern features—you can find a new machine that elevates your craft and saves you time and frustration in the long run.