A quick update; I cracked out another bleached shirt, this one based on the moogle-in-magitek-armor image by DeviantArt user Camac, straight out of FF6 for the SNES. It took some tweaking to make the pattern contiguous for the laser cutter, but not too much. A quick observation: the brand of the shirt seems to have a big impact on the minimum realizable feature size. We couldn't find the soft fancy v-necks we'd been buying, so settled on a four-pack of Haynes crew-neck shirts. They're comfy enough, but noticeably thinner and bleached substantially faster (think 10-20 seconds rather than 2-4 minutes to transition from black to maroon-pink). I stuck with the same freezer-paper and ironing method I've described previously.
For future patterns on these shirts I'll probably aim for thicker features and a finer spray at a larger distance, as I'm not totally happy with the the blurring on this one. Still, more SNES nostalgia is always good.