PCB prototype and drill-holes separated subboards

[zmaster]

Hi everybody,

this is my first post here, I figured somebody on EEVblog might be able to help me.

I've designed a "PCB business card", which has:
- my name and phone number on the top side
- some SMD breakout boards on the bottom side
The idea is that, even if the person to whom I give the business card doesn't want to call me back, at least he might find it useful.

Now, I've ordered some prototype PCBs for cheap in the past from a company in china. Unfortunately this company and another couple I've tried don't seem to accept PCBs with "subboards" separated by drill holes strips, and if they do they charge you a LOT more.
I assume this is because they want you to place different orders to make more money. I can't see any other reason why it would be (that much) more expensive to make more holes, even though they are many.

So, my question is: can I have this PCB manufactured at a reasonably low cost? Are there some companies that don't care or are there other options to make the PCB "hand-breakable"?

[sleemanj]

dirtypcbs.com for 2 layer boards should do it, internal slots too if you so desire.  Slot and mouse-bit tab routing works fine.

NB: Not for 4 layer, they use a different board house for that who won't do it (for cheap).

[zmaster]

Thank you for your suggestion.

I could give it a go. Their help page is quite confusing though:

Please note: only one separate design is allowed in each order. Panelized designs are OK for 2 layer boards only! Separate, non-connected boards will be refused by the board house!

That sounds like you can panelize only if:
1. you have multiple copies of the same design (1st sentence)
2. the board is 2 layers (2nd sentence)
3. you actually create the panel yourself connecting the subboards with tabs instead of expecting them to join separated boards in your files (3rd sentence)

My only problem seems to be point 1. But in your picture you clearly have different designs. Mmmm.

[sleemanj]

It is fine (and common) to do like i have with dirtypcbs 2-layer (but not 4 layer) :-)

See dangerousprototypes forum dirtypcbs threads about panelizing for more.

[zmaster]

I've received the boards from DirtyPCBs today.
I'm really happy with the result, except for the white being a bit off everything is great, including the tiny text in the silkscreen. The picture is not very good, the footprints are perfect.

Thank you again!

[serggio]

You need consider scribing process.
This is no drilling, this is simple cutting board by disk cutter on 2/3 depth (or more, or less, as you will ask manufacture) from both side. Scribing cheap and should be FOC for you.
Both scribing and drilling used for preparing boards for next separation after assembling.
For reflow soldering multiple boards still joined together on one big plate after PCB production process but prepared for separation.
Drilling used only for board with difficult geometry (not square boards). All PCB boards should be already processed by cutters and only small bridges between multiple boards must be present and drilled.
This is far away from that your received from your Chinese partners. When your sub-boards will be separated by breaking, you will need to do mechanical processing for each side of your sub-boards. Or you will be have inaccurate sub-boards with sharp peaks after breaking.
With scribing you will be have much better results, and no any drilling! between sub-boards. Your business card will be still look as one unit, but will be prepared for separating. 

[zmaster]

Uh, I haven't noticed your reply serggio.

I've never heard of "scribing", from your description I assume you mean V-scoring.
I've considered that option, however it can only do continuous cuts across the entire pcb and as you can see in the picture this would not work.