We cut our own stencils with a 0.010" end mill on our LPKF pcb milling machine. For material we use 0.005" thick FR4 laminate without copper, purchased in big sheets (2'x2' or so) from Insulectro (if I recall correctly). I use the same paste in a syringe that we use for the occasional manual dispensing for stenciling. I just take the needle off and dispense a bead across the width of the stencil. I made a simple frame for holding the pcb and the stencil and use a putty knife to spread the paste. We do this for complex one-off boards as well as any boards we make in multiples.
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