Yes. What you are describing is a stencil.
The military, factories, shipping companies, and maintenance crews have used stencils for over a century. The WWII method you are thinking of was often a metal stencil, but the same idea works with plastic, cardboard, acetate, mylar, or thin metal.
The process is simple:
A message is designed on a computer.
The centers of letters such as A, B, D, O, P, Q, and R are connected with small bridges so they do not fall out.
The letters are cut completely through a sheet of plastic.
The resulting sheet contains holes shaped like the letters.
The stencil is placed on fabric.
Paint, ink, spray paint, a marker, or a brush is applied.
The stencil is removed, leaving the message on the cloth.
This is a completely legitimate commercial service.
The problem is that many print shops today specialize in:
Vinyl signs
T-shirts
Digital printing
Laser engraving
CNC cutting
When you ask for "letters cut out," they may assume you want:
A printer
Vinyl decals
A cutting machine
Software
What you actually want is a custom stencil.
Useful terms:
Stencil
Letter stencil
Custom stencil
Reusable stencil
Mylar stencil
Plastic stencil
Laser-cut stencil
CNC-cut stencil
Do not ask for printing.
Ask for stencil fabrication.
Materials commonly used
Best:
Mylar sheet (flexible, durable)
PET plastic sheet
Polypropylene sheet
Acceptable:
Acetate sheet
Thin PVC sheet
Professional:
Thin aluminum stencil
For fabric work, Mylar is usually the preferred material.
Example of what to tell the shop
"I need a reusable stencil. Not a print, not vinyl lettering, and not a sign. I want an A4 plastic sheet with the letters cut completely through the material. The holes in the sheet will form the message. I will place the stencil over fabric and apply ink or marker through the openings."
Instructions for Employee
SERVICE REQUEST
I am looking for a CUSTOM REUSABLE STENCIL.
Specifications:
• Size: A4 sheet (approximately 210 mm × 297 mm).
• Material: Mylar, PET plastic, acetate, polypropylene, or similar stencil plastic.
• The text must be cut completely through the material.
• The finished product should be a single sheet containing the message as openings (holes).
• Letters such as A, B, D, O, P, Q, and R must include stencil bridges so the centers remain attached.
• This is NOT a printed sign.
• This is NOT vinyl lettering.
• This is NOT a decal.
• This is NOT a T-shirt transfer.
Purpose:
The stencil will be placed on cotton fabric. Ink, paint, or marker will be applied through the cut openings to reproduce the message.
Please provide:
Price for one stencil.
Price for multiple stencils.
Material options available.
Estimated production time.
Maximum letter height possible on an A4 sheet.
Keywords:
CUSTOM STENCIL
LASER-CUT STENCIL
MYLAR STENCIL
REUSABLE LETTER STENCIL
A4 PLASTIC STENCIL
If the local print shops continue pretending not to understand, look instead for businesses offering laser cutting, CNC cutting, sign fabrication, or architectural model making. Those businesses routinely produce exactly this type of stencil.
The military, factories, shipping companies, and maintenance crews have used stencils for over a century. The WWII method you are thinking of was often a metal stencil, but the same idea works with plastic, cardboard, acetate, mylar, or thin metal.
The process is simple:
A message is designed on a computer.
The centers of letters such as A, B, D, O, P, Q, and R are connected with small bridges so they do not fall out.
The letters are cut completely through a sheet of plastic.
The resulting sheet contains holes shaped like the letters.
The stencil is placed on fabric.
Paint, ink, spray paint, a marker, or a brush is applied.
The stencil is removed, leaving the message on the cloth.
This is a completely legitimate commercial service.
The problem is that many print shops today specialize in:
Vinyl signs
T-shirts
Digital printing
Laser engraving
CNC cutting
When you ask for "letters cut out," they may assume you want:
A printer
Vinyl decals
A cutting machine
Software
What you actually want is a custom stencil.
Useful terms:
Stencil
Letter stencil
Custom stencil
Reusable stencil
Mylar stencil
Plastic stencil
Laser-cut stencil
CNC-cut stencil
Do not ask for printing.
Ask for stencil fabrication.
Materials commonly used
Best:
Mylar sheet (flexible, durable)
PET plastic sheet
Polypropylene sheet
Acceptable:
Acetate sheet
Thin PVC sheet
Professional:
Thin aluminum stencil
For fabric work, Mylar is usually the preferred material.
Example of what to tell the shop
"I need a reusable stencil. Not a print, not vinyl lettering, and not a sign. I want an A4 plastic sheet with the letters cut completely through the material. The holes in the sheet will form the message. I will place the stencil over fabric and apply ink or marker through the openings."
Instructions for Employee
SERVICE REQUEST
I am looking for a CUSTOM REUSABLE STENCIL.
Specifications:
• Size: A4 sheet (approximately 210 mm × 297 mm).
• Material: Mylar, PET plastic, acetate, polypropylene, or similar stencil plastic.
• The text must be cut completely through the material.
• The finished product should be a single sheet containing the message as openings (holes).
• Letters such as A, B, D, O, P, Q, and R must include stencil bridges so the centers remain attached.
• This is NOT a printed sign.
• This is NOT vinyl lettering.
• This is NOT a decal.
• This is NOT a T-shirt transfer.
Purpose:
The stencil will be placed on cotton fabric. Ink, paint, or marker will be applied through the cut openings to reproduce the message.
Please provide:
Price for one stencil.
Price for multiple stencils.
Material options available.
Estimated production time.
Maximum letter height possible on an A4 sheet.
Keywords:
CUSTOM STENCIL
LASER-CUT STENCIL
MYLAR STENCIL
REUSABLE LETTER STENCIL
A4 PLASTIC STENCIL
If the local print shops continue pretending not to understand, look instead for businesses offering laser cutting, CNC cutting, sign fabrication, or architectural model making. Those businesses routinely produce exactly this type of stencil.