Will it punch cardstock?

Yes, regular card stock. I never use mine as you’re limited as to what you can do with these.

Can you punch individual letters, or does it have to be words on card stock/paper?

You can punch both individual letters, and you can punch words. You will need card stock or paper to do so. Hope that helps!

Some words have double letters. Wouldn't that be a hassle since you only get one of each letter, for when you're lining them up in a strip?

When u need to use same letter in a word leave a space then when spelling word then insert cardstock at open space to repeat letter

Can you punch thin aluminum with this? Example soda can?

I doubt it- I have trouble punching cardstock.

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