It relies on access to a laser cutter, so if you don't have one, look away now.....
I cut a plastic stencil on the laser, align it with the PCB pads and then squeegee a thin layer of solder paste through the holes.
Peeling away the stencil will leave a perfect pattern of pads with the correct amount of solder on each one.
I have just successfully used this process on components with a 0.025" pitch (0.65mm) - that's VERY small,
The prototype in the pictures has been made by my good friends at Spirit Circuits in the UK, and is a full plated through, double sided board. with immersion silver coating.
Step 1: Prepare the artwork
Here, I'm using Number One Systems "Easy-PC", which may look very familiar to anyone using DesignSpark's free offering.
Turn OFF all the other layers, turn ON the mask layer, change the output device to "plotter" and plot to file. I mirrored the mask, but I am not sure its important. Technically, the holes benefit the process if they are smaller on the TOP of the stencil than the BOTTOM. This ensures a clean peel at the later stages