Apply printer toner directly on a blank pcb, using 5W laser to bind selected tracks to copper.
Method:
Black toner powder (from HP P1102 Laserjet). Mixed it with surgical spirit, to form a liquid with the consistency of ink. The more alcohol used, the more the ink tends not to cover certain bits (see pic2). Increased density of toner mix, until there was less spreading of ink (pic3).
When pcb has dried up, I put it under a laser gantry (5W) that traces out pcb.
Workflow I use is Kicad>Flatcam>bCNC.
Kicad track size of 0.01. However, Flatcam isolation routing results in each track getting burnt twice. bCNC/grbl feed speeds of F30 @ 800mm/min setting
Results
Pros: Toner Tracks are bound to copper. Brushing out does not dislodge them.
Cons: The tracks are quite thick. Tracks cannot pass between 100mil DIP pins. Track to track clearance chosen in this Kicad project, is too small.
1. Applying toner method using spray method or maybe immersion method (help needed)
2. Use faster settings in the grbl during laser firing. F30 is slow and heat might be propagating outside of point of incidence. Therefore more toner is melting than required.
3. Change flatcam to fire tracks only once. Isolation tracing fires each track segment twice.
4. Reduce pad/via size
5. Once visually acceptable, one can also try to etch this.