>
> Back to the toner transfer method. All my transferring was done using an
> iron. Sometimes it stuck, sometimes it didn't. Fine traces never did.
> Paper type made huge amounts of difference, could never find the right kind
> I guess, even after reading many of the posts here. Maybe the laminator
> will make a difference, but I'm still up against paper selection and line
> widths. Perhaps you can shed some light on this, since the transfer method
> may improve my making 2 sided boards. Now that would definitely get my
> attention.
>
I've used several different methods and so far the toner transfer has been by far the simplest, and I can use cheap surplus board stock instead of the expensive photosensitive boards which I never seem to have in the size I need.
There are a few critical points, one is the right combination of printer and toner, another is proper preparation of the board prior to transfer, and another is the transfer technique.
I use a $25 laminator now and have excellent results, I use my Xerox laser printer (OEM toner) to print on glossy catalog paper, most recently an old catalog from Action Lighting which has been working better than any other I've tried. An iron works too, but it's more difficult to get it consistent.
Clean the board with circular scrubbing with a Scotchbrite pad until it has a matte finish, then wipe it off with a paper towel dipped in acetone. Cut out the pattern you printed down to just a couple mm beyond the edges of the board. Lay the pattern on the blank board taking care not to touch either the printed surface or the clean copper. 8 passes through the laminator then dump it in cold water. After 5 minutes or so peel off the paper, sometimes you have to scrub it, but the thin really glossy stuff from the lighting catalog just floats right off and leaves a perfect transfer.
As with the photo process, once you tune the technique, you can get very consistent results. For fine pitch SMT stuff photo is likely superior, but toner transfer is nice in that you can whip up a board from concept to finished product in just a few steps and very little time for under a dollar in materials.