Laser-Cut Solder Stencil
No solder stencil? No problem! Turn an old business card into one using a laser cutter.
Late last year I got a laser cutter, and not too long after that I decided to step into the world of surface-mount PCBs. While not having leads that allow you to fudge a poorly placed location, along with parts that are so small that you have to manipulate them with tweezers is intimidating, the benefits are definitely worth it. One challenge, however, is getting solder paste in all the right spots, without smearing extra paste all over your board.
For this purpose, you can order a solder stencil that fits over your PCB, and lets you "squeegie" the paste into place. I didn't order one for my first surface mount PCB, and I actually haven't ordered one period. Instead I've been producing my own using a laser cutter and business cards.
The process, as outlined in the video below, involves plotting out the proper layer as a DXF, then importing it into the LightBurn laser cutter software package. Set the proper power and speed (60/35 here), place a business card on the cutting surface, and press the Start button. A few seconds later, you have a custom solder stencil!
Of course, business cards aren't the only option for DIY solder stencils. Wesley T. Honeycutt made his own with Kapton tape. Jason Lopez creates stencils with transparency film, burning the holes instead of cutting the outline. Both seem like great options, though there's a good chance you have a business card at the ready right now!