I have one of those plastic stencil burners somewhere. I don't remember if I ever used it. I vote for the heavy vellum or Golden Threads paper. I don't like marking my quilts so usually use the Golden Threads paper to sew on. It tears away easily.

Having been a "wood burner" for many years (eighteen years of a home based business where wood burned art was our best seller) and almost eighteen years since then, I do not recommend regular wood burners for plastic stencils. You will have a hard time getting a smooth edge or an even design unless you practice a "LOT!!!!!!" and wouldn't you rather be quilting? There were special stencil burners but I have not ever used one and now do not even know if they are still being produced. There must be an easier way. Listen to the experts, like Margo and have fun. Hugs, Ann

Thanks everybody. Looks like I have all the tools right in my sewing room to give this a try. I will go with the treadless needle and vellum first because I have those things. I knew that 100 needle was sitting in my sewing drawer for some good reason. Not home right now but I hope to have time to try this tomorrow. I am getting ready to quilt my GMFG (hexies) quilt. I am afraid my poor Mug Rug friends are getting all my trial designs as Mug Rugs. They aren't quite wall worthy but would look much better with a few cookie crumbs on them, not to mention coffee stains. They are meant for use. I thought I had my final design yesterday and sent some out with that design. After I slept on it wouldn't you know the design changed. Now I have a better idea how to mark the design. The video tutorial on Golden Threads was great. Thank you everyone for your help. Marilyn, I am with you. I try to do as little marking as possible, but sometimes you just need help to know where you are going.

Same methods here,too. I don't do it any more than I have to, tho.....

Just thinking...could you use the needle-punch technique with lightweight template plastic? I'm thinking it would give you a more durable product (as long as sewing thru plastic wouldn't damage your sewing machine. :shock: ). It seems to me that I have seen people post negative comments about both the wood-burning and double-bladed tools for making stencils, but I can't remember if saw it in the Forum or elsewhere.

I have tried both the wood-burning tool and Exacto knives, and didn't like the results either time, and find the I do better just using my sewing machine!

I don't use the really hard template plastic for this, but I mark the stencil with a sharpie, then unthread my sewing machine and using the largest needle I have, just stitch along the lines! You can do it with the feed dogs up, or drop the feed dogs and do it with free motion. Use a long stitch length so you don't just perforate the template plastic. You can also use Golden Threads paper the same way.

This video might give you some ideas: http://www.goldenthreads.com/

Lois, I had good luck with the heavy vellum (not the stuff of paper-piecing, but more like the inserts to wedding invitations), tracing the pattern with a fine Sharpie, stitching with a 90 needle, then pouncing on the rough side. This held up very well.

I want to make a plastic stencil to use with a pounce pad or marking pencil or pen. How do you cut through the plastic? I read about double blade cutting tools and about using a wood burning tool to melt through the plastic. Have you had experience with either? What brand cutting tool or wood burner have you used? What do you recommend. Thanks.