Step 6Notes and Variations
If you don't have a laser cutter, and can't build one, it is possible to print out the halftoned images and cut by hand. See Sten and Lex, The Wooster Collective, Bonard's MLK, ctrl84, RatherNotSay and AlexLionheart. They tend to use squares instead of circles for the halftone, which makes it a lot easier to cut by hand.
The thinner the material for your four layers is, the easier it will be to get paint in the holes. If you cut overhead projector film (normally polyester) instead of chipboard, there's the added advantage of washability. Even though with the chipboard I didn't have any issues with the paint gooping up the tiny holes.
T-shirts? I haven't tried, but have a feeling there'd be a lot of bleed.
With a thin enough material, you might be able to paint over the layers instead of spraypainting.
I initially imagined this as a cheap way to do larger-scale full-color printing on various surfaces. So long as you have access to a laser cutter, that's still a reasonable idea. If you can't get the laser parts for the DIY laser cutter, you could try making a machine that just prints stencils using some kind of vinyl/plastic/polyester and a soldering iron to burn the holes. (Purely speculative, watch out for fumes.)
Thanks to Bart Woodstrup for helping me with the Illustrator exporting and laser cutting.
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