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Home Made 30 Watt Laser Table Sep2007
These instructions are partially wrong…I've been cutting stencils from Eagle files for about a year. He's right about the Eagle PDF export causing problems, I've been using Inkscape to open it and save in a format Corel understands.
The main thing he's wrong about is the actual sizing of the cream outlines. You can see a lot of his pads actually overlap, this will allow too much solder to be deposited and cause bridges during reflow. Due to the kerf left by the laser cutter you need to shrink the outlines by a few mil. I usually go into the DRC Mask section, and on the Cream part I set a max of 10mil and a percentage of 20% or so. Then export the cream layer.
For 2mil mylar on a 45 watt laser, I tape the plastic on smooth birch plywood and cut the outlines in vector mode with 8% speed and 3% power. That seems to eliminate most of the melting and rough edge problems people complain about with mylar. It actually sticks most of the chads to the plywood, so when you pull off the stencil it automatically weeds most of them.
Here's a picture of one stencil I made:
And here's a video of cutting a stencil recently: http://www.twitvid.com/5F80B