I also have to get my 2¢ in. In fact, I was a lurker following this thread (and others) who was compelled to register just for this reply!
The service is a unique and valuable service. The target customer base is well-defined and, unfortunately, never going to be the size of McDonalds’, for example. This will always be a challenge to making the profit you likely desire!
There are, of course, intangible values to this service as well. For example, I, personally, choose to buy products from SFE because of this service. (You could even imagine “frequent shopper” points from SFE redemable via BatchPCB to entice more of the same!). The ease, accesibility, professional results and just plain “coolness” of BatchPCB should encourage more projects, i.e., repeat customers (for parts and PCBs).
Lastly, I echo the “teaching aspects” of the service as posted by previous people. I would have LOVED to had the chance to make such boards as part of class projects. Perhaps it is even possible to “spin off” this company as a not-for-profit educational venture??? The tax savings alone may be more valuable than automation!
And iff customer volume is what you desire, then ADVERTISE!!!
I only stumbled across SFE as a by-product of my new interest in PICAXE products. Otherwise I never would have heard of you! Ad space in college newspapers, for example, is pretty affordable! (But the best advertisement may be through us cheap professors…)
With all that said, I have to admit that I have used the service for the first time only recently and am anxiously awaiting my board (totaling $23). I decided to use the service because of price, first and foremost; but also because I could have a professionally-made board, including multilayer with silkscreening, rather than the “amateurish” one-sided, poorly drilled thing I would have made for myself. Even if the first version doesn’t work (should I start a pool?); I’m far more likely to keep this as a personalized $20 bookmark than anything I would have done myself!
Good luck with the service!
And let us know how it goes.