Yes, we’ve seen our share of tutorials for making solder paste stencils, but [Felix] hit it out of the park with this one. It’s the definitive guide to making solder stencils at home, with quality as good as you would find in any professionally made stencil.
The material for the stencils comes from the same source as so many other DIY solder stencils – aluminium cans. The interior plastic coating and the exterior paint job are both removed with heat, acetone, and patience. After laying out the cream layer of his board in a PDF file, [Felix] used a fairly interesting transfer medium to get the toner onto the aluminum; cheap vinyl shelving paper attached to a piece of paper apparently makes for an ideal surface to transfer toner.
After transfer, the board is etched with HCl and peroxide. [Felix] is getting some very good results with his method, including a few very fine pitch IC footprints. It’s just as good as a professionally made, laser cut stainless stencil, and you probably already have all the necessary ingredients lying around your house. That’s a win anytime.