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I'm glad to see he calls out thin soldermask. This is the bane of my existence with every single PCB manufacturer--even the expensive ones.

I have had innumerable problems because the soldermask doesn't mask. If you have some big pad (QFN, DPAK, etc.) and you route a line requiring soldermask isolation next to it you can expect to have some percentage of the boards fail. It's infuriating, but at this point I just have to assume that it simply will happen and design around it.



Dry film, photo imageable solder mask, like Dupont VACREL, may be a better choice.




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