gEDA-user: SMD soldering challenge status

[DJ Delorie <dj@xxxxxxxxxxx>]

I've been poking at this idea on and off, I think I have a viable plan
in place, except that Olimex is on vacation this month, and they're
the best bet for getting the boards cheap enough, assuming they can do
0.40mm pitch (7.87 mil) with their 8 mil rules.  If I have to go with
a more expensive fab, I can fiddle with the parts list to compensate.

The board is 16 by 10 millimeters (small!) single sided with sample
parts down to 01005 caps and 0.40 pitch ICs:

      http://www.delorie.com/pcb/smd-challenge.html

At qty 100, the cost is just under (by a few cents) $2 per kit.  I
figure, I can tape all the parts to a piece of paper, and have folks
send me a check and a self-addressed stamped envelope.

The questions are: What footprints to use for a proper "challenge"?
We've got four each for the 0201 through 0805 parts, and I can make
the two ICs have either long or short pads.  Plus, what about solder
mask?  What's ideal?  Or should we make it more challenging (and
perhaps cheaper) by not having one at all?

I'm also figuring score-and-snap to separate the boards.  I can leave
a bigger border if I go to double sided.

Comments?


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