The material you make your stencil from matters almost as much as the design itself. A stencil printed on thin copier paper will last one use before it turns soggy and tears. A stencil cut from 200gsm card will survive twenty uses and still give you clean edges. Here's what to use for each situation.
Standard printer paper — for single-use stencils
Standard 80gsm copier paper is fine if you only need to use a stencil once or twice — for a birthday card, a gift wrap project, or a one-off test before committing to a wall. Print, cut, use once, and discard. The moment it gets wet with paint it starts to soften, so you won't get many passes from it. That said, for quick disposable stencils it costs nothing and works perfectly well.
Card (160–200gsm) — the everyday workhorse
This is the sweet spot for most home crafters. Heavy card stock — the kind sold as "card" at craft shops or used for greetings cards — is thick enough to hold its shape through several uses, stiff enough to keep its edges flat against the surface, and still cuts easily with scissors or a craft knife. Print your stencil onto card, or print onto paper and trace onto card before cutting. Aim for 160–200gsm.
Tip: Laminating a card stencil after cutting extends its life dramatically. A laminated stencil can be wiped clean between uses and will last an entire school term of classroom activities.
Acetate or Mylar film — for serious repeated use
If you're going to use the same stencil dozens of times — for a repeating wall pattern, a business logo, or a favourite craft design — it's worth transferring your design onto clear acetate (overhead projector film) or Mylar (a flexible polyester film available from craft suppliers). Both can be wiped clean repeatedly and will survive far more use than any paper or card. Mylar is slightly more flexible and generally preferred for curved surfaces.
To transfer: print or trace the design onto the film in permanent marker, then cut with a sharp craft knife on a cutting mat. Alternatively, use a cutting machine like a Cricut with suitable blade settings.
Stencil blank sheets
Most craft shops sell pre-cut stencil blank sheets specifically designed for making reusable stencils. These are typically 125–190 micron thick, semi-translucent, and come in A4 or A3 sheets. They cut cleanly and clean up easily. If you want a proper reusable stencil without the cost of Mylar, these are an excellent option.
What about printing direct onto card?
Most home printers will handle card up to around 200gsm without jamming. Check your printer's manual for the maximum supported weight and use the manual feed tray if your printer has one. Printing directly onto card saves the step of tracing and is perfectly reliable for most designs. For very intricate designs, print onto paper and carefully trace — fine detail is harder to see through thick card.
Quick summary
| Material | Best for | Reuse |
|---|---|---|
| 80gsm printer paper | Single-use, quick projects | 1–2 uses |
| 160–200gsm card | Regular craft projects | 5–15 uses |
| Laminated card | Classroom, repeated projects | 20+ uses |
| Acetate / Mylar | Repeating patterns, professional use | 50+ uses |
| Stencil blank sheets | Dedicated reusable stencils | 30–50 uses |
Frequently asked questions
Can I print a stencil onto card in a normal home printer?
Yes — most inkjet and laser printers handle up to 200gsm card. Use the manual or rear feed tray and select "card" or "thick paper" in the printer settings. Test with a single sheet first.
What is Mylar stencil material?
Mylar is a brand name for biaxially-oriented polyester (BoPET) film. It is tough, flexible, and transparent, making it ideal for durable reusable stencils. It cuts cleanly with a craft knife and can be wiped clean many times.
How do I stop a card stencil from going soggy?
Apply paint sparingly with a nearly dry brush — the wetter the application, the faster the card softens. Wipe the stencil clean with a barely damp cloth between uses rather than soaking it.
Is there a difference between acetate and Mylar?
Acetate (cellulose acetate) is slightly stiffer and clearer, while Mylar (polyester film) is more flexible and tear-resistant. Both work well as stencil materials; Mylar is generally preferred for long-term repeated use.