1. PCB Express (Sunstone) - 4 layer board, 3 day turn, 2 3x3" boards for $169. Add 50% cost for 2 day turn.
*After plating; the surface copper thickness will be a minimum .0014 thickness on the outer layers.
12mil prepreg -> 22.5mil 50 ohm trace
2. Advanced Circuits - 4pcb - 4 layer board $66 each, one board min. student offer (otherwise 4+1free min order), 5 day turn.
http://www.4pcb.com/index.php?load=content&page_id=242
http://www.4pcb.com/media/-062%204%20layer%206-9-2010.pdf
set thickness ( 62 - 4*1.35mil for copper - 40mil core) / 2 = 8.3mil
8.3mil prepreg -> roughly 15 to 16 mil microstrip:
Boards should be electroless nickel immersion gold (ENIG)
Recommended pad size is 5 x 10 mils.
Make an extra large soldermask opening around the bondpads (ex, 10mil on each side).
Die attach pad size should be 250um larger than IC, on each side.
They prefer if you keep bondwire angle less than 45 degrees, you can do this by staggering pads in two columns.
Track thickness converter:
1/2 oz.
1 oz.
2 oz.
0.7 mils
1.4 mils
2.8 mils
50 Ohm Trace Calculator:
a. change er to 4.2 for 2ghz
b. set metal thickness, Tmet = 1.35 mil for 1oz copper or 0.7 mil for 1/2 cu
c. set thickness as per process - see below
Ultra-low cost manufacturers won't score your boards. Cutting with a hack saw is dangerous to your health due to glass fiber particles.
Some shear (guillotine) cutters for under $1000:
MEGA 3205034 SHEAR, PCB, 30CM - Farnell
8" Bench Top Shear/Brake Central Machinery - item#90757 - Harbor Freight ($200)
OA-Shear - T-Tech
kester solder paste, refrigerated
cheap toaster oven
450 degrees, wait for shiney flowing solder, let cool slowly
check with microscope... apply paste to unconnected pads, reflow.
warning, may be toxic, hazardous, or fatal, do at your own risk.
If your board outline (keep out layer) doesn't show on the gerbers, make sure "keep out layer" isn't selected in the line (track) properties.
To redefine the board shape from the keep out layer box, you can select the box quickly via Edit->Select->All on Layer (after having activated the keep out layer)