>Something that since I have extensive experience with, and the destruction
>one can cause trying to dispose of spent ferric chloride, I do NOT want to
>be involved with ever again.

The guys here etch PCBs with a mix of muriatic acid and hydrogen 
peroxide, which is much easier to deal with. Google "muriatic acid pcb 
etching" for more info-- our version is here:
http://milwaukeemakerspace.org/2012/04/pcb-with-lasered-paint-resist-and-fast-sponge-etching/

Note that we're using 30% H2O2 rather than the 2% you typically find at 
a pharmacy (I don't know where they buy it). Supposedly you can 
"regenerate" the acid mix by bubbling air through it, but we've never 
gotten that to work, so we just mix up a new batch each time.

Instead of photo resist, we use black spray paint, and etch the paint 
away with a laser cutter.

We've tried cutting circuit boards with a CNC engraving machine, with 
varying results. The main problem seems to be keeping the board 
absolutely flat-- it tends to warp, and then you don't get a consistent 
depth of cut. There is a method of "height mapping" the board ahead of 
time, and using the computer to compensate while engraving. I don't know 
the details, but it does seem to work. I think it's a plug-in for Mach3. 
Very careful mounting might also work.


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