Solder stencils are a fantastic way to accurately apply solder paste to a PCB. Professionally-made stencils are cut from steel, but for the home hacker, soda cans continue to be the alternative of choice. The only trick is how to actually get those little holes made, and [Saheen Palayi] shows off both his method of laser-engraving the holes, as well as a tool for cutting the can in the first place.

To turn a soda can into a flat-ish aluminum sheet means cutting off the ends and slicing it open. Ideally, one achieves this without kinking or bending the thin metal. In practice, this is quite difficult. [Saheen]’s solution is something a little like a pipe cutter — a 3D printed tool that gradually presses a blade section from a utility knife into the empty can as it turns until it cuts through. Once the top and bottom are off, it’s easy enough to snip down the side to get a curved sheet.

The hole pattern comes from one’s PCB design software of choice, and the actual cutting is done by a fiber laser. The wavelength of fiber lasers makes them good at marking and cutting metal, and [Saheen]’s laser takes almost no time at all to cut the stencil into the thin metal.

Fiber lasers used to be the sort of tool that only industrial shops had, but they’re a prosumer-level tool that can be bought online nowadays. [Saheen] uses an xTool F1 Ultra to cut his solder stencil, and we’ve previously seen that same laser used to create a PCB by blasting away unwanted copper until only the traces remain.

We’ve seen aluminum cans etched and also machined to create stencils, and the laser is certainly the fastest. Watch it in action in the video below.