How to Guide for Custom Stencils
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If you are using your custom lettering stencil on outdoor surfaces, concrete floors or other high traffic areas, we suggest using a little more spray adhesive and using it more often. If the surface is porous or dirty the tack level will need to be greater. In this case you will want to make sure the stencil is securely stuck to the surface as different sprays, marking inks and rollers can produce different results. Please practice first!
Always ask yourself, what paint will you be using?
Every paint has specific instructions on how to use it, what surfaces it can be used on, drying time and clean up. Please carefully read these instructions and if possible, practice using this paint on the type of surface you will be painting.
- If using spray paint, do not hold the can too close to the stencil. Paint can build up on the edges and run underneath the stencil. Practice holding the can 8-10 inches or more away from the stencil and gently waving the spray side to side. We have found this technique gives the most control over how much paint is applied an allows a gradual build up of color.
- If using liquid paint and a roller, we suggest high-density foam rollers. These high-density foam rollers are designed to apply less paint and not “load” on the paint like a traditional nap roller would. Remember, if you are painting a surface and want to COVER it with paint, use a nap roller. If you adding paint through a stencil, use a high-density foam roller.
- If using dry-solid stencil paint you will need a stencil brush. There are separate instructions that come with dry-solid stencil paints that should be followed. These include wiping away the skin coating on the surface of the paint, wiping off excess paint and drying time for various surfaces.
- If using marking inks and ink rollers, please follow the instructions on the ink or ink roller package.
- Using ink pads. Using Ink pads with our high-density foam rollers is a great way to control how much ink and color you apply to a surface. Roll the foam roller several times across the ink pad and then roll onto a paper towel to determine how much ink the roller contains. Begin stencil rolling and use a softer touch to apply less ink initially. You can lift the stencil and gauge how dark the color is. You can always go back over the stencil a second time pressing harder on the roller to make letters darker. High density foam rollers are ideal for these applications and allow for great control of inks, paints and stains.
What Is Blank Mylar?
Blank mylar is a clear, flexible polyester film that's used as a stencil material across a wide range of industries and applications. It's durable, reusable, and holds a crisp, clean edge that transfers beautifully to almost any surface. Whether you're cutting your own designs by hand, with a craft cutting machine, or using it as an overlay material, a mylar craft sheet gives you a professional result that cardstock or paper can't match.
Because it's see-through, blank mylar also makes alignment easy, a huge plus when precision matters.
Why Order a Custom Size?
Standard sheet sizes work great for a lot of projects, but sometimes you need something a little different. Custom blank mylar sizing is a practical solution when:
- Your design is larger than a standard sheet
- You're cutting shapes in bulk and want to minimize waste
- You need long, continuous runs for borders or repeating patterns
- You're working with an industrial or commercial application that requires consistent, oversized material
- You want to match a specific substrate or format for production work
Whatever your reason, we're here to make it happen without any hassle.
The Applications Are Almost Endless
Our blank mylar custom-size sheets are used across a surprisingly wide range of projects. Here's just a small sample of what customers use them for:
- Home décor and DIY crafts: Create repeating wall patterns, furniture stencils, and decorative accents with a polished, store-bought look
- Sign making and lettering: Cut your own lettering stencils for wayfinding, retail displays, and event signage
- Pavement and floor marking: Thicker mylar holds up to repeated use on rough surfaces like concrete and asphalt
- Industrial labeling and safety marking: Used by facilities managers, warehouses, and plant operations teams who need reliable, reusable stencil material
- Screen printing and art projects: Mylar's smooth surface and dimensional stability make it a go-to for artists and printmakers
The clean lines you get from mylar are noticeably sharper than what you'd get from paper or acetate; it's one of those small upgrades that make your finished work look genuinely professional.
How to Place Your Custom Request
Ordering your custom blank mylar size is straightforward. Just fill out the request form here with your desired dimensions, thickness, and quantity, and our team will get back to you promptly with pricing and availability. We manufacture everything right here in Old Saybrook, CT, which means faster turnaround and direct communication; no middlemen, no guesswork.
Not sure which thickness is right for your application? Give us a call at 1 (800) 334-1776, and one of our product specialists will walk you through the options. We're available Monday through Friday, 8 AM to 6 PM EST, and we genuinely enjoy helping people find the right material for the job.
