CadCircuits
Take a circuit that you know reasonably well, design it in Eagle PCB or Express PCB.
Make a schematic file, make a board file
Chemical etching:
print the board file, you can use ferric chloride to remove the unneeded copper, leaving just the connections you need.
Milled pcb
make the board file, send to micromill, remove unneeded copper, leaving just the connections you need.
PrintedCircuitBoards has a few ways to make your own circuit board.
Here is some info on Eagle:
http://www.instructables.com/id/EZ3WN1QUKYES9J5X48/?ALLSTEPS
http://www.instructables.com/id/EN4JHYI8R7EYF7IYHZ/?ALLSTEPS
http://www.instructables.com/id/E65LY13F03FMNR9/?ALLSTEPS
a sample file - http://electricity.pbwiki.com/f/motorcontroller.zip
eagle to g code - http://www.brusselsprout.org/PCB-Routing/
here are some other links
- http://falstad.com/circuit/ has some great visualizations
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