Resources

https://learn.adafruit.com/smt-manufacturing/laser-cut-stencils

How to Laser Cut a PCB Solder Paste Stencil on Kapton

In brief, convert gerber to SVG using gerbv. Transform features in inkscape. Send SVG/PDF file to printer. Laser cut in vector/raster form. Ozbotz seems to have amazing resolution using raster.

Settings on EngPhys laser cutter

Vector Cut – 30% Power, 30% speed, 600ppi works and cuts through 2 mil kapton. Proportional power increase for increased thicknesses? ppi can be increased.