Frequently Asked Questions

Most of our materials for custom stencils are polyfilm (Mylar). (See why Mylar below)  We have laser cut many different materials to find the perfect product and we find that mylar works the best! It is flexible, and won’t break like thicker materials. The most commonly used types of mylar are:
7 mil (white): A medium weight material as thick as card stock. This material is thin enough to achieve outstanding detail when stenciling, yet strong enough to clean and use many, many times. All of our pre-made alphabet stencils and, unless otherwise requested, all of our decorative lettering stencils are made from this material.
10 (mil white): This material is a standard material used for our industrial stencils. It is tear-resistant yet flexible. It can be cleaned easily to provide a very long life. Customers who buy this material use their stencils for shipping crates, tool/equipment marking, floors/parking areas, and many other industrial applications. 14 (mil white):This is the thickest of our polyester material and it is truly a “work horse” for a durable stencil. Typically, our customers are more than happy with either of the lighter materials. The 14 mil mylar is best used for long-term us stencils with minimum fine details.  
We do stock thicker and more rigid plastics, however our mylar materials, listed above, are usually the best choice for stencils. We do not cut on any type of metal.  
Why Mylar? The three things you want to consider when choosing a stencil material are: How strong is it? – Mylar is quite strong. It has the ability to be rolled very tightly and it will always bounce back to its flat shape. If you take a square sheet of mylar, even the thinnest 7 mil, you will not be able to tear it using your hands. How easily can it be cleaned? – The secret to a long stencil life is the ability to clean paint or ink off your stencil. Mylar is one of the very few plastic materials that is solvent proof. You can clean your stencil with paint remover, acetone (fingernail polish remover), turpentine/mineral spirits, or anything recommended to clean paint. Will it achieve crisp stenciling results? – All material in the mylar family is flexible. This is very important when you are stenciling because it can conform to curved surfaces as well as the subtle variations on flat services. This will provide a more crisp and professional look than you can achieve using a rigid stencil material.
The largest letter size we can cut is approximately 60″ tall. The smallest is approximately ¼”. We can cut some basic typestyles as small as 1/8″ but the typestyles and configurations are limited at this size.   If you are unsure if we can accomplish the sizing you are looking for, please email the details of your project to us or submit your information to us via our Quote Request Form.
We can use almost any typestyle if you can provide us with artwork we can easily use. We can work with a TrueType font file that you provide to us or we can use a vector file that you have already converted to curves. You can email us to see if we have the typestyle you are looking for already available.
The current maximum cutting area for our lasers is 96″x48″. Layouts that exceed this area will be produced in multiple parts. Each section will include registration marks to maintain proper alignment. We do not recommend taping sections of stencils together; instead, we recommend you use each section separately if you are doing a large stencil project.   We can customize the dimensions of your material to any specifications you need.
For an outstanding selection of graphic, decorative and airbrush stencils be sure to visit   We also have a small collection of stock graphics available within our Custom Stencil Designer.
We do not have any adhesive stencil materials.  Adhesive materials are limited in the number of times you can use them.  Some of our customers use stencil adhesive or repositionable spray adhesive, which is available at any craft store and most hardware stores.  This adhesive is perfect to use with our stencils because it can be completely removed from the stencil… allowing you to use it more than once.   We do not sell metal or magnetic stencils.
Stencils Online ships orders over $75 FREE in the USA  | Orders that total $75.00 or over will qualify for free shipping with the US. 
  • Most orders will ship via USPS First Class Mail (2-7) business day transit time + order processing time).
  • Orders that weigh over 1 lb. may ship via USPS Priority Mail or FedEx Ground/Home Delivery.
  • Any order that is deemed oversized by FedEx may require additional handling charges.
Unfortunately we are unable to accept refunds or exchanges on custom orders because they were created specifically for you and can not be re-sold. It is important that you check the sizing, spelling, and complete details of your layout prior to completing your order.   
We strive to achieve 100% customer satisfaction and if there is a problem with any of our custom stencils, we will work with you as much as possible to make sure your stencil will work with your project. If you are unsure if using a stencil is the best approach for your project, contact us via email or phone and discuss your application with the professionals first.   
We can accept returns or exchanges on stock inventory items within 30 calendar days of receipt if the stencils are un-used or manipulated (i.e. painted, cut, or bent). Your order will be refunded for the total cost of your order minus the shipping. If you do need to return an item to us, you are responsible for re-shipment charges for returns and exchanges.    To return an item to us, please ship the stencils to the below address. Please include a copy of your invoice with a note requesting an exchange or refund.  
Stencils Online, LLC
ATTN: Returns / Exchanges
70 Industrial Park Dr 
Suite 7
Franklin, NH 03235
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