Stenciling an oddly shaped board (was: small quantities of GC10?)

[NorthGuy]

Interesting. How much would you enlarge the outline relative to the real board? Zero? 10 mil? Presumably tight is good but interference fit is perhaps going to be too much.

I would probably go for 6 mil. Tighter fit will help stencil alignment. But too tight will make it difficult to take the board out. It always can be corrected with Dremmel if needed.

[mrpackethead]

Tab routing is not 100% accurate. you'll need to allow for the variation in accuracy of both 'PCB's

[Koen]

Add two small holes in the PCB. Add them to the stencil. Order dowels 0.05mm smaller. Stack three PCBs, insert dowels, add stencil, print. No machine, no jig, no frame.

[Harjit]

@Koen - on the shape @djacobow showed, how would you do that?