I am wondering what is the best way available in the space to cut reusable/durable stencils from vector images. Is there a cost effective material we can use with the laser?
If by best you mean free and by durable you mean wont fall apart immediately, we have lots of large cardboard sheets that are free to use (in project storage near ryobi shelf).
Thanks, now I know what to use to practice the the use of the laser.
Let me better define the two parameters 
Cost effective: Something that I can buy in bulk and will last for several stencils. On the other hand free is always better.
Durable: A material that can be sprayed “indefinitely” without braking apart. This probably means some type of plastic.
1/8" hardboard would be an option
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is it a stencil for paint or and abrasive mask? I’ve the the real thin plastic cutting boards before, them for a buck or two. Especially good because if curved surface they are flexible. But have only used for paint. Not sure how abrasive jobs they’d do, but a multiple of vinyl would be my guess. No idea what they are made of other than they are food safe … but maybe not laser safe.
Mostly for painting but a solution that can work for both is preferred.
Would something like this work? If wikipedia is correct these are made from cellulose acetate, but I have no idea if it’s safe to cut with the laser cutter.
I doubt overhead transparency film has actually been cellulose acetate any time in the last decade. It is most likely polyethylene, and should laser cut with no issue.
I will give it a try then and update this thread. For $0.16 per letter size sheet I think it’s worth the try. Do you expect this to be usable as an abrasive mask as well?
Probably not going to have a good life as an abrasive mask. By abrasive, you planning to sandblast? If so, just keeping it in place is a bear. I’ve used “spray mask” vinyl as a sandblasting resist in the past, but it is single use.
Yes, sandblasting is what I am thinking, but you are right that it’s going to be hard to hold, especially on a curved surface.
Reusable is going to be nigh-impossible. Otherwise, cutting out a sticker on the Vinyl Cutter is a tried & true method. There’s even a class on it once in a while.
The mask is going to need to stick down pretty well to whatever you’re applying it to, otherwise you’ll get paint or dust under the mask anyway.
I have used this material for stencils in the past by cutting it with an X-acto knife. The idea is to use the stencils with an airbrush or even with a normal brush.
I hope that if sprayed vertically and without too much air pressure it won’t have any underspray. Another option is to use a spray adhesive to assist the hold down of the stencil.
https://www.amazon.com/Blank-Stencil-Making-Sheets-Frosted/dp/B00085FACK
Might be an option… I have purchased several stencils to use with my airbrush and they are typically made out of a similar material. I don’t know whether or not it can be cut on the laser, though. We do have some acetate sheeting in CA. For sandblasting, adhesive vinyl would be the best route and who needs durable when can reproduce them quickly and cheaply with the electronic cutters in CA.
@mreynolds is doing a class on sandblasting stainless steel tumblers so he would probably be a good person to talk to.
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Mylar is trade name for one formulation of polyethylene.
May have issues melting rather than cleanly cutting, but can’t hurt to try.
Once we get software for the Cameo Silhouette in the closet, it’s an smaller format electronic cutter, it can cut that stencil blank material if you want them for painting.
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Apparently one of our members has already successfully cut mylar (polyethelene) with the old FSL laser cutter
With the suggestion of @Nick I purchased this https://www.signwarehouse.com/c/oracal-oramask-813-stencil-film While it’s a one time use, I believe you should get some great results with it. It’s available in the CA room - in a box below the regular film. Price is the same $2 a linear foot (payable to the vinyl cutting box).
Keep us informed on the results.
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Mylar Brand polyester is safe to cut on the laser. I made a bunch of little washers out of 16 mil Mylar. I’m referring to non-reflective Mylar. You can get it really thin or somewhat thick. In general, check the Material Safety Data Sheet (MSDS) on the web for any flammability or toxic or caustic gases that might be released. 16mil will hold up against the sand blaster but doesn’t bend well for objects like glasses. It would be good for air brushing. It can get a little bit brown on the edges with the laser cutter if you use too high a power setting. I have not tried using the 2mil stuff but I can’t see that it would have any advantage over vinyl. By the way, you cannot cut vinyl on the laser. It releases chlorine gas which can kill you and will hurt the laser.
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813 is reusable, the trick is not stretching it when applying and removing it.
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Thank you all for your replies! I will check the cheap transparency films first (since they are safe) and if that doesn’t work I will test one of the other suggested options. Anyway I will update this thread!