I've looked several times over the years for a good freeware package, although I haven't actually tried setting down to evaluate all of them by completing designs in each
I look for 2 things
– the ability to do 4-layer board layouts –The extra layout freedom of gnd and pwr layers is too “cheap” in added pcb cost for the number of boards I’ll ever have made vs the superior performance and layout time savings to pass up
-usable part libraries are absolutely critical for getting a project done, yes you will likely have to edit/create 1 or 2 new parts so that process has to be usable but a good library of standard parts is essential
ExpressPCB - a fatal flaw for me is the lack of "rubber banding"; the live connectivity lines showing the (nearest) pins that are connected, and that stretch, move, reorder to new nearest connection while you arrange the parts - absolutely critical for finding the part placements that minimize sensitive nodes, reduce coupling and make for a superior layout
Vutrax – commercial but with a attractive sounding 256 pin free version limit, I was unable to “get it” about the user interface, even went to the extreme of reading the documentation and trying the tutorial! But 20+ hrs of nite/weekend poking at it left me without the 1st clue about how the design flow was intended to work
KiCad is a relatively new open source tool with a promising level of activity, but while the user interface and documentation seem better than Vutrax the “friction” was still too high for me
gEDA and PCB are older open source projects that some claim work but I haven’t found active user forums/dev “buzz” that makes me trust that they are supported and generally usable, I use Windows PCs so a requirement to build the current version of the doc is a non-starter for me
When I wanted to design a pcb in finite time with high probability of success I just bought the standard version of Eagle, the interface is “quirky” but somehow fits my expectations enough better than Vutrax and KiCAD that it was tolerable, the forums and 2 support phone calls let me generate schematic, BOM, 4-layer board layout with 200+ parts in ~1 week from first trial – with only 2 layout errors in the 1st board
I am deliberately not providing links, If you can’t find these and their user forums with google you haven’t much chance of successfully completing a project with any of them
My opinions may be out of date or reflect my own search incompetence, please weigh in with any useful info – I would be happy to ditch Eagle if a clearly superior alternative was available