Dear propellanttech
Thanks for the directional advice. I think for the next circuit that uses QFN or similar I will try a .003" or .004" S.S stencil instead of the .006" S.S one I have just used.
Is see my paste does indeed have an 88.5% solids ratio.
The circuits I have done with mylar had low component density and nothing finer than an SSOP PIC chip. However it worked fine for me. Perhaps I was lucky not to get much “flash”. Andy at smtstencil.co.uk made my Mylar stencils.
If your design is fixed, you can also move to a stainless steel stencil, especially in the quantities you’re dealing with.
I did’nt every try to use a plastic stencil for “fine” work. I think it would be pushing your luck a bit far.