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DIY PCB fab with UV laser engraver - need router/drilling machine

2384 1 Dec 13.2019, 18:35:24

I am considering an experiment to make DIY PCBs. The goal/purpose of DIY is primarily to make fixtures for tests and assembly as well as working out various circuit designs that cannot be bread-boarded. 
The technical needs are modest - double side, no mask, no silk. Not sure what minimum trace width I can get away with, but nothing crazy. With all that out of the way - I have reviewed all the usual DIY PCB methods out there (even made a few when I was a kid). They are all too time consuming and/or fiddly to be interesting until I considered the option of using my Epilog laser marking machine to replace the transparencies, toner transfer, exposure part of the process. The laser can go up to 1200dpi and have a dot circle of around .003" / .076mm. 
I was thinking that I just buy pre-sensitized PCBs, put them in the laser, out of the laser into developer and etching. On paper, it sounds fast and easy but I may be naive about what it is really like. I saw a YT video where someone did a PCB in a similar way - looks like a good idea since I already have the high resolution laser system which is the majority of the cost. 
Also, one of the goals is to be able to deal with the fact that the majority of my PCBs are not squares. If I am going to work out a prototype shape with connectors, wiring, hardware and full assembly testing before sending for fab - I would need a router to both cut the outline as well as drill the holes. Any recommends for a reasonable quality router with very high-speed spindle would be good. There are a ton of super cheap, super crappy/fiddly options out there. It would be nice to have a step-up from the bottom, but not a super amazing top-of-the-line model either. I did my best to 3D model everything including fasteners, but until I build a few with real parts, hardware, and wires - it was not known if it could be assembled. Tiny details matter and being able to quickly spit out 5-10 PCB shapes to optimize production assembly process would be a great time saver. Even the fastest PCB fab is a few days and at that speed it is top price of at least a few hundred per pass between the fab and overnight shipping. If I have 4-5 interconnecting designs, it could be significantly more money in addition to the time. 
I may be crazy, but this seems cheap to try. Any tips from those that have done any of this would be great to hear.

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