Lamination process of making PCB is very easy and cheap, but the most important is, that is not nasty process. Here you can see how it's done.
Design and print
First we have to design the PCB layout and print it on white paper. This is one way to check if it is ok and also give us the position of the PCB.
Now when we have the design on a normal white paper, we can continue with process. For laminating process, we need low quality thin and glossy paper. Paper that grocery store are using as advertise paper (not sure how it’s called in English) it’s thin and glossy. Don’t worry for prints on paper it does not come down during a lamination process. Now cut the piece of paper and tape it on printed PCB design.
Print PCB layout
Put prepared paper into printer and print PCB layout again over thin paper. We have to print with laser printer! Then cut out the thin paper.
Cut the PCB board in dimension of the PCB layout and put layout on board with printed side.
For this step, we need laminator. Some laminator we can used as they are because they provide enough temperature power. If the laminator is not providing enough big temperature, then we have to rework it. We have to take out original thermostat and implement new adjustable one.
Heat laminator to 170 - 180 °C, measure temperature between rubber rollers, not on heater! Make few passes through roller. The toner have to stick to copper.
When the printed layout is on copper, put board into water. The best is warm water. Help yourself with finger and roll off paper. Do no scratch or use any hard stuff to get rid of paper! Toner is not resistant to any physical damages!
At this step the PCB board is ready to etch! Put the solution into plastic bowl with board and etch PCB. You can also use NanoFish aquarium that is described in projects 🙂 The solution is from one part of water, two parts of hydrochloric acid and one part of hydrogen peroxide.
At the end we have to get rid of on board toner. Use sponge and scratch it down, now you can use all the methods that have been forbidden in step "Removing paper" 😀 You can use acetone or any other remover, but, be careful! My toner get from copper but it get stuck to the board, then is all black. I prefer hard sponge.