What is the Best Thickness for Stencil Film

Common Film Sizes:

1 millimeter = 1000 microns

T-shirts and other garments, curtains, wall hangings.

Just as in fabric painting 3 mil to 4 mil is sufficient.

The best answer for this question is "as thin as you can get". unless you have a good reason to want a thick stencil material, for example, if you are plastering a raised design through a stencil or making a parking stencil. For just about all other stenciling work a material of around 3 to 4 mil will do the trick.

A stencil material that is durable, easy to cut and holds good detail and is over 4 mil is difficult to find on the retail market. The most commonly available films that are suitable for repeat stenciling are usually around the 3 to 4 mil range. They include acetate film and polyester film otherwise known as Mylar or drafting film (my favorite).

The real issue in most cases is not so much thickness as durability. some folks believe that thicker means longer lasting. Not so....keep in mind that we are using these stencils as a simple mask to paint through.

If you fold a crease in a stencil, irrespective of how thick or thin it is, you will ruin it. If you let paint dry on it for weeks, it will be difficult to remove.

If you walk on it or drive your car over it repeatedly, then it wont last very long. Thin film like 3 mil drafting film will last for many years and hundreds of impressions, if you look after it, treat it with respect and clean it carefully after using it..

1. .002" 2 mil 50 Micron
2. .003" 3 mil 75 Micron
3. .004" 4 mil 100 Micron
4. .005" 5 mil 127 Micron
5. .007" 7 mil 175 Micron
6. .010" 10 mil 250 Micron

Ideal Stencil Thickness for :

Fabrics: 3 mil to 4 mil

Wall painting: 3 mil to 4 mil

The only advantage of going thicker is a little extra managability..

Airbrushing: frisket

Frisket is a very thin, self adhesive film suitable if you are cutting the stencil directly onto the artwork. Otherwise use drafting film.

Canvas Art: 3 mil to 4 mil

Plaster Stenciling

Here you require something a bit thicker: at least 10mil and preferably thicker 10 mil ( 250 micron) and upwards.

Industrial Stencils: Polypropylene

Difficult to cut large pieces, but very durable. Use polypropylene up to 3mm thick.