I'm going to need a few double-sided SMT prototype boards in a few months, with a more constant need for prototype boards after that. Maybe I'm lucky, but I have a choice of methods. In addition to a laser printer with toner transfer paper, I've got a small CNC machine I could repurpose as a PCB Mill, a few small vinyl cutters (Which I've never used, but would like to), and an old flatbed pen plotter that I actually used 15 years ago to make a carrier board for a small SMT connector. I'm looking for opinions for the best/easiest/quickest/most reliable method. I wouldn't mind getting a cheap inkjet and try the direct-print method, or hacking up an old laser printer for direct print toner. Milling sounds great in theory, and replacing the bit with a drill means precision drilled holes as a bonus, but the mess and noise is a bit of a turnoff. Transfer paper with a Laser printer worked in the past, but aligning the second side is always hit and miss. I never tried inkjet, and it sounds really interesting, but it looks like an almost-solution, with the ink not really resisting the etchant without extra work. I just came across the vinyl cutter method, where you cut the traces out in vinyl and transfer them to the PCB to etch, and it sounds interesting, but not sure how easy or reliable it is. I'm leaning towards using the plotter, as it seems there will be a little less 'playing' with ink that works, and I've successfully used it to make some pretty fine traces in the past.
While I don't mind etching, I'm looking for as close to "hit print, get a reliable and cheap board spit out' kind of thing, with little setup or cleanup.. Has anyone used any/all of these methods? What was your favorite?
Thanks!