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Jun 15, 2015 at 19:59 comment added Josh The components that have to be laid out sparsely over a large area can definitely be single-sided, and the rest can be on a small, more complex board. I'll definitely have to look into single-sided and phenolic, thanks!
Jun 15, 2015 at 19:51 vote accept Josh
Jun 15, 2015 at 19:43 comment added Spehro 'speff' Pefhany +1 Paper-base phenolic can be much cheaper especially punched- it's priced by the square meter not square inch or cm. Of course if you're only buying a few square meters that won't help, but it's not necessarily stupid high quantities- definitely worth looking at changing the specs if phenolic is good enough and if you're looking for 10K pieces or so (per shipment). Solder mask and silk screen won't add much cost. Shipping by air will be more costly for big boards because the mass is larger. Paper phenolic is lower density, but usually it gets shipped by surface (eg. ocean freight).
Jun 15, 2015 at 19:35 history answered user16324 CC BY-SA 3.0