Stencil Making & Laser Cutting

0.25 inches (6mm) is the safe minimum. Thinner lines may not cut completely or may be fragile. For fine details, use mylar instead of plywood—it tolerates thinner cuts better.

Plywood stencils: 50-100 uses before wear. Sealed plywood: 200+ uses. Mylar: 50-80 uses. Longevity depends on paint type (acrylics last longer than oils), cleaning frequency, and storage conditions.

Yes, but only with a fiber laser (not CO2). Aluminum and stainless steel work well. Metal stencils last 500+ uses but cost more and require specialized laser. Consider metal for high-volume, long-term projects.

Incomplete cuts occur when: laser power is too low, speed is too fast, material is too thick, or lens/mirror is dirty. Increase power by 5-10%, decrease speed slightly, or add a second pass. Always clean optics first.

Use thin, even paint layers and hold the stencil firmly in place with spray adhesive. For very fine edges, seal stencil edges with clear caulk before use. Work from dark surfaces to light to catch bleeding early.

Store flat in a dry, cool place (not in direct sunlight). Use cardboard dividers between stencils. Avoid moisture exposure, which causes warping. Label each stencil with date and material for easy identification.