I make my own printed circuit boards (PCBs) using Press-n-Peel toner transfer sheets from http://www.techniks.com/ The process is repeatable, and produces excellent quality boards suitable for prototypes. With my HP Laserjet printer, I can reliably produce boards with track widths down to 10 mil. The PnP material requires only modest heat to transfer the toner (the "silk" setting on the iron), light pressure and about 2min. for a 2" x 3" board. In addition, the PnP material uses the normal laser printer settings, there is no advantage to setting the printer toner setting to "dark". Once the board has been etched and drilled, I tin plate the board using a tin plating solution available from MG Chemicals.
Here is an example board for a 32 pin TQFP package (the AT90USB162):
Here is an example board for a 32 pin TQFP package (the AT90USB162):
Here is another board that contains a CP2103 USB to RS232 bridge chip from Silicon Labs. This is a 28 pin QFN package (5mm x 5mm with 0.5mm pitch pins):
This set of boards makes up the Russian Nixie project. This gives you an idea of the complexity of the boards you can make. The lower board supports a 64 pin TPFP package:
