Another day another idea....
I wasn't wow'd by the stencil tests. I was thinking what I suggested for John Stevenson about laser cutting masking tape, then I thought what about if you spot burn the tape like dot matrix lettering. Well for us without lasers use a pin on the masking tape. In my case put a signature on the tape in pen, stretch the tape over a glass then use a pin to poke holes in the tape.
The problem with using a pin is that when you press the tape down, you haven't removed material so the hole can get filled up with tape again. Still, worth a try.
Not too shabby for a first try, you can see some holes failed to etch, but the principle is sound. It took about a minuite to etch in 20 second presses as the contact area is so small. Having a power supply or meter so you can read current is a must, its the best guide to how your etching is going and what sort of time to apply the tool for. In this case I was only seeing 10ma, hence the much longer application. Thinking about it, the wife has one of those fancy sewing machines that can also do a bit or embroidery stitching, including lettering. Hmmm whilst the cats away could I "empty" stitch the paper tape to make my stencil ??? Sorry guys that isn't going to happen any time soon as you would never get to see the results or ME again.