> Interesting topic. Instead of cutting the copper directly, how about
cutting some
> vinyl or maybe masking tape? Then transfer the cut vinyl or tape to a
copper
> clad FR4 board. Or maybe better yet, bond the tape or vinyl to the copper
clad
> FR4 and then cut. Remove the unwanted vinyl or tape and etch the board. I
> have not tried this technique exactly, but have done a few boards with
hand cut
> tape. If the etchant doesn't leak under the tape or dissolve the tape, it
works
> fairly well. The trick might be to find the right tape, perhaps Kapton
tape, or
> wide electrical tape?
Ordinary sign vinyl would work for the usual through hole size stuff, you'd
have trouble on really fine tracks.
That's how a lot of etching (on glass etc) is done, cut the pattern, stick
it on whatever you're etching, and then apply the etchant or sand blast it.
(The sign vinyl is quite thin, the stuff used for sand blasting tends to be
thicker.)
It'd be a bit easier than toner transfer, apart from picking out all the
unwanted bits.
Tony