Stenchill: Free 3D-Printable PCB Solder Paste Stencils from Gerber Files

Stenchill is a new free web tool that turns Gerber PCB exports into 3D-printable solder paste stencils. Upload a ZIP of your Gerber files (from KiCad, Eagle, Altium, etc.), preview the stencil in 3D, and download an STL ready for your FDM printer. No sign-up, no cost — just a browser and a printer.

How it works

The workflow is dead simple: drag a Gerber ZIP onto the page, tweak a few settings if needed, and grab the STL. The tool automatically generates registration shoulders for alignment and optimizes the stencil geometry for FDM printing. A KiCad plugin is also available to launch generation directly from the PCB Editor.

Target audience: makers and small runs

Stenchill is explicitly designed for prototyping and small-batch production, not high-volume manufacturing. It works best with 0603 and larger passives and coarse-pitch ICs. For 0402 or fine-pitch BGA, a laser-cut stainless stencil remains the better choice. But for quick-turn boards where you'd otherwise use a syringe, this is a massive time saver.

The recommended print settings are sensible: 0.2mm nozzle, 0.1mm layer height, 100% infill, Arachne wall generator, and 30–40 mm/s print speed. PLA or PETG on a smooth bed. Stencil thickness should be 0.3–0.4 mm (3–4 layers).

Why this matters

Professional stencils cost $15–30 per side plus shipping. Stenchill is free and gives you a stencil the same day — no waiting for couriers. It's also a lifesaver for legacy boards: if you have old Gerbers but no stencil, you can generate one in seconds without reordering the PCB.

The project was born during a Twitch stream by French maker Barbatronic, who now uses it in his own workflow. The community feedback so far is positive, with users reporting successful soldering results for both personal and work projects.

Limitations

This isn't a replacement for professional stencils in production. FDM-printed stencils have inherent roughness and limited resolution. But for the prototyping loop — where speed and cost matter more than perfection — Stenchill fills a real gap.

The tool is in beta and available now at stenchill.com.