...On the other hand for quick and dirty prototypes (even double sided), a tool like EASYPC and a reasonable laser printer gives great results.

You can get EASYPC in a very functional, but cut down total pin numbers for the $60 budget I think.

We used EPC with 500 pins limits to do the tightest board our external board shop has ever seen: which was 0.008" tracks and spaces, two 64 pin TQFP and two 28 pin SOICs on just over 2 square inches. Even with all the bells and whistles EPC only costs $400, and that includes a working autorouter and schematic package.

You still need access to a decent printer and some HEAT RESISTING transparencies, forget paper, the dimensions change enormously with distance along the board, and you'll be hard pressed to get a large dip package to line up, let alone an SMT package. Don't use the wrong transparencies. Laser fusing units aren't cheap.

We don't use acid for the etch, but ammonium persulphate, which gives a really sharp etch line, down even to 0.010" tracks and separations, but you need a very good (600dpi plus) laser printer to make a sharp enough transparency. Feric Chloride works well, but it stains and dissolves fabrics. I have many pairs of cutoff shorts....

It is VERY important to print the artwork so that the toner is in contact with the board. In the interest of helping you I won't say why.

I really mean it about the transparencies....

Steve