How much does it cost per hour to run a fiber laser cutter?

A 6kW fiber laser costs approximately $12-18/hour to operate including electricity ($5-8), assist gas ($3-5), consumables ($2-3), and allocated maintenance ($2-3). This is based on single-shift operation at $0.12/kWh electricity. CO₂ equivalent is $25-38/hour. The exact cost depends on material, gas type (nitrogen vs oxygen), and cutting parameters.

What is the biggest operating cost for a laser cutter?

For fiber lasers: assist gas (nitrogen/oxygen) is the largest single cost at 30-40% of total operating expense, followed by electricity at 25-35%. For CO₂ lasers: electricity is the largest cost (35-45%) due to lower wall-plug efficiency (10-15% vs 40-50% for fiber), followed by assist gas and laser gas mixture refills.

How much electricity does a fiber laser use vs CO₂?

A 6kW fiber laser consumes approximately 12-15kW total (wall-plug efficiency 40-50%). A 6kW CO₂ laser consumes 40-60kW total (wall-plug efficiency 10-15%). At $0.12/kWh for 2,000 hours/year: fiber = $2,880-3,600/year, CO₂ = $9,600-14,400/year. Fiber saves $6,000-11,000/year in electricity alone.

Laser Operating Cost Comparison: Fiber vs CO₂ Total Cost of Ownership

⚡ Key Takeaway

A 6kW fiber laser costs $15,000-25,000/year to operate vs $35,000-55,000/year for equivalent CO₂. Over 5 years, fiber saves $100,000-150,000 in operating costs alone, offsetting any purchase price premium within the first 1-2 years.

Operating cost — not purchase price — is the true differentiator between laser technologies. A machine runs for 10-15 years, and annual operating costs often exceed the original purchase price within 3-5 years. This analysis breaks down every cost category based on real production data. For technology comparison beyond cost, see our CO₂ vs Fiber Laser Comparison.

Published: February 11, 2026

Last Updated: February 11, 2026

Skill Level: Production Manager / Finance

1. Annual Operating Cost Breakdown

Based on 2,000 operating hours/year (single shift), $0.12/kWh electricity, nitrogen assist gas at $0.25/m³.

Cost Category	6kW Fiber	6kW CO₂	Fiber Savings
Electricity	$3,000-4,000	$10,000-14,000	$7,000-10,000
Laser gas (CO₂ mix)	$0	$3,000-8,000	$3,000-8,000
Assist gas (N₂/O₂)	$4,000-8,000	$4,000-8,000	Similar
Cutting nozzles	$800-1,500	$800-1,500	Similar
Protective lens / window	$500-1,200	$1,500-3,000	$1,000-1,800
Focus lens	$300-600	$600-1,200	$300-600
Mirror / beam delivery	$0 (fiber delivery)	$2,000-5,000	$2,000-5,000
Chiller maintenance	$500-1,000	$1,000-2,000	$500-1,000
Preventive maintenance	$2,000-4,000	$5,000-8,000	$3,000-4,000
Total Annual Operating Cost	$11,100-20,300	$27,900-50,700	$16,800-30,400

2. Cost Per Operating Hour

6kW Fiber Laser

Electricity:$1.80-2.40/hr

Assist gas:$2.00-4.00/hr

Consumables:$0.80-1.65/hr

Maintenance:$1.25-2.50/hr

Total:$5.85-10.55/hr

6kW CO₂ Laser

Electricity:$5.00-7.20/hr

Laser gas:$1.50-4.00/hr

Assist gas:$2.00-4.00/hr

Consumables:$1.45-2.85/hr

Maintenance:$3.00-5.00/hr

Total:$12.95-23.05/hr

3. Five-Year Total Cost of Ownership

Including purchase price, installation, and 5 years of operating costs at 2,000 hours/year.

Cost Component	6kW Fiber	6kW CO₂
Machine purchase	$250,000-400,000	$200,000-350,000
Installation + training	$15,000-25,000	$20,000-35,000
5-year operating costs	$55,500-101,500	$139,500-253,500
5-Year TCO	$320,500-526,500	$359,500-638,500
5-Year Fiber Savings	$39,000-112,000

Note: This analysis excludes revenue differences from fiber's faster cutting speed. When accounting for throughput (fiber cuts 40-300% faster), the effective cost-per-part advantage of fiber is significantly larger than the operating cost difference alone. See our Cutting Speed Chart for speed data.

4. Cost Reduction Strategies

Gas Cost Optimization

• Install nitrogen generator for shops using > 15 cylinders/month (payback: 12-18 months)

• Use oxygen assist for carbon steel (faster + cheaper than nitrogen)

• Optimize nozzle standoff to reduce gas flow rate by 15-25%

• Use shop air for thin mild steel (< 2mm) at 30% cost of nitrogen

Consumable Life Extension

• Clean protective windows daily — extends life 2-3× over "run until failure"

• Monitor nozzle condition with centering test; replace proactively

• Store spare optics in climate-controlled cabinet (humidity < 40%)

• Use correct focus position to prevent premature window contamination

Frequently Asked Questions

How much does it cost per hour to run a fiber laser?

A 6kW fiber laser costs $6-11/hour including electricity, gas, consumables, and maintenance. CO₂ equivalent is $13-23/hour. The largest single cost for both is assist gas (nitrogen or oxygen).

What is the biggest operating cost?

For fiber: assist gas (30-40% of total). For CO₂: electricity (35-45%). Installing a nitrogen generator can reduce the largest fiber cost by 40-60% for high-volume shops.

How much electricity does a fiber laser save vs CO₂?

A 6kW fiber uses 12-15kW total vs 40-60kW for CO₂ (3-4× less). At 2,000 hrs/year and $0.12/kWh, fiber saves $6,000-11,000/year in electricity alone. This is because of the much higher wall-plug efficiency: 40-50% for fiber vs 10-15% for CO₂.

Related Guides

CO₂ vs Fiber Comparison

Full technology comparison

Fiber Laser Advantages

10 reasons fiber beats CO₂

ROI Calculator

Model your specific cost scenario

Cost data based on 2025-2026 North American market pricing from multiple equipment dealers and production facilities. Electricity rate: $0.12/kWh (US average industrial). Gas pricing: bulk delivery rates. Individual costs vary significantly by region, supplier contracts, and utilization patterns.