Lots of discussion about making your own and having 'em made.

I make all my own prototypes.  Unless of course they're more than two
layers of copper or extremely tight.  It's not really all that tough.
I've made hundreds of prototypes with the methods I'm gonna describe:
First get a good layout package.  I use PCPRO/EZROUTE from AMS.  Protel's
free (that's right freeware) layout is also quite nice for these
purposes.  if you're gonna be having boards made in quantity (by a
boardhouse) you'll wanna make sure your layout package can do REAL gerber
output and excellon drill files.

To make your own:
Print out your artwork on drafting vellum right on your laser printer...
haven't tried inkjet, but i don't see why it wouldn't work.  The Vellum
is thermally stable unlike acetate sheets, and has no trouble passing UV
for exposing presensitized boards.  (I've tried several of the toner
transfer products and have had poor or unpredictable results with each.)
I get my vellum at Office Depot for about $7 for a pad of 50 8.5x11"
sheets... it's cheaper than acetate too!
Take your printout and expose your pcb (slug).  I use a twin 24"
flourescent fixture from home depot with 2 20w GE blacklights in it.  My
glass of my exposure jig (from mouser i think) is kept about 3" from the
bulb surface and I expose the blank for 10 minutes.

If your board is double sided, reverse (mirror) the image of the top side
of the board.  Trim the edges (where no image is) on one of the plots,
then register the two sides using backlighting and tape it in two or
three places to keep the two images registered... insert the pcb slug
between the sheets and tape it in place (rather tape the vellum sheets to
it) too.  When you've finished exposing one side, flip it and expose the
other.

Develop the board and etch it.
FWIW I use kinsten (from Circuit Specialists in Mesa, AZ) single and
double-sided blanks (positive process-presensitized) with kinsten
developer and use ammonium persulfate (mouser) to etch.  Of course
double-sided boards will require you to make your own vias... Use small
(#28 or so) solid copper wire and solder to both sides.

Drilling is made relativell easy with a dremel and dril press accessory
(the dremel drill press is about $50 at home depot or sears (may be a
special order)) and a decent selection of PC board bits.

Hope this is helpful... if you want any more details or sourcing info,
email me:  mike@hagans.com


Mike Hagans
CircuitWerkes