I used KiCad[0] PCB design software and followed a lot of Youtube tutorials. This[1] one was the best tutorial I found, it seems pretty trivial at first glance but touches on all the parts of the process.

I use OSH Park for the actual PCB production[2], they're pretty cheap and good quality boards but be prepared for a bit of a wait. There's also a good price comparison site[3] for alternate suppliers.

[0]http://kicad-pcb.org

[1]https://www.youtube.com/playlist?list=PLy2022BX6Esr6yxwDzhqY...

[2]https://oshpark.com

[3]http://pcbshopper.com

I started on KiCad but found the interface very unintuitive.

I got stuck at the point of making my own footprints for custom devices, which I needed to do because the library doesn't seem to include all that much (or maybe I couldn't find devices I was using because I couldn't work out the UI for searching well enough.

Might have another go at some stage.

Thanks!