Software

• CADSoft Eagle is the most popular PCB design software on the low end
• Circuit People is a free online gerber viewer

Instructions

• Hackaday has a good howto on prepping your design for manufacturing
• SparkFun has a great series of tutorials on Eagle for PCB design
• Eagle: Schematics
• Eagle: PCB Layout
• Eagle: Creating a new part
• Sooner or later you’ll want to read the SMD Soldering tutorial
• If you have the means, Photo Etching is an option if you need it immediately
• Simpler but time consuming is the Toner Transfer method
• YouTube tutorial on toner transfer from Make magazine

Fabrication Services

• BatchPCB specializes in small runs and has great prices
• PCB-Pool is a similar service for small orders
• When you’re ready to make them in bulk, Gold Phoenix looks good
• Olimex is another choice for proto runs