Bed-of-Squares Prototype PCB

Over the years I have tried various methods (Ugly Construction, Manhattan Construction, Perf-board, etc.) to make PCB layouts for one-off projects and initial design prototypes. Of all these the pre-cut PCB squares glued down to blank PCB substrate seemed cleanest and easiest to use, but still lacked efficiency and flexibility for modifications when ideas changed or when redesign was necessary. Because of this nagging desire for improvement I have came up with my own quick way to make simple "bed-of-squares" pro-typing PCBs from blank PCB stock.

The method is simply to cut a mass of equal squares on blank board surface by inscribing lines through the copper surface in a rectangular pattern.

https://drive.google.com/file/d/0B7Xo5h2IkKGqU0kxTDVhUGQzbmc/view?usp=sharing

https://drive.google.com/file/d/0B7Xo5h2IkKGqbmJMRUE0cExJdzQ/view?usp=sharing

https://drive.google.com/file/d/0B7Xo5h2IkKGqQ3VWSU5DTVdYTWs/view?usp=sharing

https://drive.google.com/file/d/0B7Xo5h2IkKGqNXVHRVB2SmZzVVE/view?usp=sharing

Here is a Pixie transceiver built on a "Bed-of-Squares" and placed inside one of my 'test jig' platforms.

https://drive.google.com/file/d/0B7Xo5h2IkKGqU3pDaXRrRFZKME0/view?usp=sharing

Here is the tool that I use to scribe these rectangles into blank PCB stock. It includes a board with aluminium strip guides along the sides and an aluminium strip across the top at mid point. This top guide strip is carefully placed at right-angle to guide strips on the sides. The top guide strip is placed at mid-point on the block to support use by either right or left handed individuals, and to allow making bed-of-squares PCB layouts that extend to the edge of a section of blank stock.

https://drive.google.com/file/d/0B7Xo5h2IkKGqbGNTaHZjOHFidEk/view?usp=sharing

A scribing tool was made from a section of hack-saw blade by cutting a notch into it at approximately 45 degree angle (see picture). This allows using the scribe tool at proper angle to quickly cut through the copper.

NOTE: It is possible to scribe very deeply into blank PCB stock to facilitate breaking it over a table edge or other square edge. If the resulting broken edge is a bit uneven it can be smoothed with a file.

Later NOTE: Recently I completed construction of a CNC Mill and have begun using that with a pointy bit to make Bed-of-Squares proto-boards. This involves some simple G-Code scripts, so no CAD layout is actually involved.