One potential client from Etsy was wanting a custom stencil. So I have been exploring the possibilities of using recycled billboard vinyl for this purpose. Billboard vinyl has internal fibers that do not always get cut by the Cricut Expressions. I experimented with multi cuts as well, but the fibers seem to persist. I also learned that big loops require joins or bridges or whatever the term is for stencilling. Otherwise the large loops will shift during stencilling and produce an unsatisfactory result.
The making of the stencil required a doubling/displacement/combining/anchor-point-deletion of the words "Love" and "loved" because some parts of the letters were too thin at that scale to cut well. The Arial fonts required joins or bridges on letters like "e" and "a" and "g" because they had internal space within their letters and they needed solid material to anchor those central holes.
I think that a larger design with not too many fine cuts would work well for making stencils, and I'm definately going to use it myself for my own stencilling.