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In practice, the (object) stencil is usually a thin sheet of material, such as paper, plastic, wood or metal, with letters or a design cut from it, used to produce the letters or design on an underlying surface by applying pigment through the cut-out holes in the material.
In 1880, Edison obtained a further patent, US 224,665: "Method of Preparing Autographic Stencils for Printing," which covered the making of stencils using a file plate, a grooved metal plate on which the stencil was placed which perforated the stencil when written on with a blunt metal stylus.
Steel engraving is still done today, but to a much lesser extent. Today, most printing is done using computerized stencils instead of a steel plate to transfer ink. An exception is currency, which is still printed using steel dies, since each bill then has a character and feel that is very difficult for counterfeiters to duplicate.
The stencil life is defined as a time period in which there will be no significant change in the solder paste material characteristics. A solder paste with a longer stencil life will be more robust in the printing process. Actual stencil life for a paste should be determined from the manufacturers' specifications and on-site verification.
Screen printing is a printing technique where a mesh is used to transfer ink (or dye) onto a substrate, except in areas made impermeable to the ink by a blocking stencil.A blade or squeegee is moved across the screen in a "flood stroke" to fill the open mesh apertures with ink, and a reverse stroke then causes the screen to touch the substrate momentarily along a line of contact.
The size and shape of the metal particles in the solder paste determines how well the paste will "print". A solder ball is spherical in shape; this helps in reducing surface oxidation and ensures good joint formation with the adjoining particles. Irregular particle sizes are not used, as they tend to clog the stencil, causing printing defects.
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