I've done a over one hundred boards with a Kapton stencil without any problems
(0603 size parts) and 50 boards with a stencil cut out of vellum paper (a
plasticized paper available at craft stores, red cuts very well with 405nm
lasers) by my home-made laser cutter head for a desktop CNC mill. I've never
worn one out or ripped one... YMMV. I'd probably go with stainless steel for
something with tiny BGA's, but have done chip-scale IC packages with paper
stencils. It's only recently that small stainless steel stencils have become
easily available and cheap.
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Laser cut Kapton are fine for a few boards - up to 5 or so. You start
seeing the effects of use after six or eight and steel is clearly a
value. . I use them for most protos.
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