Stencil Settings Cheat Sheet
Baseline line weights (at roughly a 10 cm finished size), minimum bridge widths, resolution, and materials for the main stencil methods. Scale weights up for larger pieces; anything below ~0.5 mm tends not to transfer.
| Application | Outline | Internal | Detail | Min bridge | DPI | Material |
|---|---|---|---|---|---|---|
| Tattoo stencil | 2 mm | 1.4 mm | 0.7 mm | — | 300 | Thermal stencil paper (e.g. Spirit Classic) |
| Spray-paint stencil | 2.5 mm | 1.8 mm | 1.2 mm | 2 mm | 300 | Mylar (reusable) or cardstock / poster board (one-time) |
| Cricut / vinyl-cutter | 2 mm | 1.2 mm | 0.8 mm | 1.5 mm | 300 | Stencil vinyl (Oramask 813) or Oracal 631 (indoor) / 651 (outdoor) |
| Screen print | 1.8 mm | 1.2 mm | 0.6 mm | 1 mm | 300 | Photo emulsion on mesh, or cut vinyl for simple designs |
Tattoo stencil: Print or trace at 100% scale, mirror the image, solid black lines.
Spray-paint stencil: Black-only at 100% scale; add bridges so islands stay connected; cut with a sharp blade.
Cricut / vinyl-cutter: Cut at 100% scale; weed carefully; bridge closed shapes (O, A, e) so centers don't lift.
Screen print: Print a black-only film positive at maximum opacity, 100% scale; expose and wash out.
Starting points, not strict rules — test on a scrap and adjust for your machine, ink, and surface. Use with your own or properly licensed artwork; respect copyright and trademarks. These figures are guidance only.