Homebrew PCBs

I asked in another thread if anyone thinks
it is a good idea to do a pros and cons
document.  If we can agree on the pros and
cons of each method - it might be able to
be included in the files section or something.

ANYWAYS - I am going to make a start with my
thoughts.

Everyone feel free to add/argue/flame and we
can see if we can all agree on anything.

Methods proposed for inclusion

Established - 
Well set up photo-shop
Makeshift photo-shop
Established toner transfer setup
Makeshift toner transfer
Silk Screen
Direct Draw Resist (non CAD/CAM)

Experimental -
Inkjet direct
EDM

(are there any I missed ?)


Method 1 - Well set up photo-shop

Pros
Best qlty boards of all methods (6/6th or better ?)
Good line defenition
Lends itself to double sided / multi layer / PTH
Easy to do small batch production
Consistant results
Little need for "experimenting in setup"

Cons
Cost of setup may exceed several 1000
Takes up a lot of space
is expensive for one off prototypes relative to TT
Requires photo chemicals (even if safe still required)


Method 2 - Makeshift photo shop

Pros
Cheap to setup (unless in antartica and no sun)

Cons
Much experimenting to get good results
Results can be variable. (good one day bad another)
Don't expect boards better than 16/16thou
Requires chemicals (even if safe still required)


Method 3 - Established Toner Transfer setup

Pros
Very good results if setup well (8/8 thou ?)
Can do double sided (with care)
Consistant results acheivable
Relativly cheap setup (in the 100s of $ mark)

Cons
Can take a lot of experimenting to get it right
Relies on manual labour in board cleaning
Has fixed cost per board (batch runs do not
   get cheaper as paper is used for each board)
Can have bad line defenition (a big problem as
   you approch 8/8thou)
requires more intensive visual inspection for
   problems than photo does


Method 4 - Makeshift Toner Transfer setup

Pros
Zero dollar set up (borrow a laser)
(other people can help me fill in)

Cons
Very variable results
(other people can help me fill in)


Method 5 - Screen print

Pros
Cheap per board for large runs
(other people can help me fill in)

Cons
As much equipment needed as photo
very poor resolution relative to TT or photo
Slow to dry / low throughput
(other people can help me fill in)


Method 6 - Direct draw resist (non CAD/CAM)

Pros
Zero dollar set up
(other people can help me fill in)

cons
very poor resolution
very time consuming
(other people can help me fill in)


Method 7 - EDM
The "experts" in this feild may like to comment

Method 8 - Inkjet direct
The "experts" in this feild may like to comment