A Good DIY Solder Stencil Begins With a Cleanly-Sliced Soda Can
A DIY method for creating solder stencils from soda cans is demonstrated using a 3D-printed cutting tool and a fiber laser. The process involves cleanly slicing the aluminum can into a flat sheet without kinking the metal. A fiber laser is then used to rapidly engrave the precise hole patterns required for the PCB design.
- ▪A 3D-printed tool functions like a pipe cutter to slice soda cans cleanly without bending the thin metal.
- ▪Fiber lasers are effective for cutting metal and are now available as prosumer-level tools for home use.
- ▪The specific laser used in the demonstration is the xTool F1 Ultra.
- ▪The hole patterns for the stencil are derived directly from the user's PCB design software.
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| Original publisher | Hackaday |
| Canonical URL | https://hackaday.com/2026/10/03/a-good-diy-solder-stencil-begins-with-a-cleanly-sliced-soda-can/ |
| Publication time | Sat, 03 Oct 2026 23:00:29 +0000 |
| Retrieval time | 2026-10-03T23:04:28.432Z |
| Last seen | 2026-10-03T23:04:28.432Z |
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A Good DIY Solder Stencil Begins With A Cleanly-Sliced Soda Can No comments by: Donald Papp October 3, 2026 Title: Copy Short Link: Copy Solder stencils are a fantastic way to accurately apply solder paste to a PCB. Professionally-made stencils are cut from steel, but for the home hacker, soda cans continue to be the alternative of choice. The only trick is how to actually get those little holes made, and [Saheen Palayi] shows off both his method of laser-engraving the holes, as well as a tool for cutting the can in the first place. A good result starts with cutting a can cleanly, thanks to a 3D-printed tool. To turn a soda can into a flat-ish aluminum sheet means cutting off the ends and slicing it open. Ideally, one achieves this without kinking or bending the thin metal.
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Excerpt limited to ~120 words for fair-use compliance. The full article is at Hackaday.
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