matthew180 wrote:
I can't really increase my PCB size, [as] I am bound by the 600mil package of the original 40-pin DIP IC that my board replaces.
Have you thought about putting parts on both sides?
I've been using DirtyPCBs for hobby stuff and even prototypes at work for the less-complex boards. Three days ago I just ordered 120 boards of 1.250"x.800", two-layer, which will get SMT parts mounted on both sides, tightest pitch being TSSOP, for $52 total, including shipping and expedited service. Vias are tented. DirtyPCBs used to accept .005"/.005" trace/space, but they've gone back up to .006"/.006" because they had too many bad boards at .005"/.005".
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Now that parts costs have come down, and the capabilities I need are available at hobby levels, I can finally make the board I wanted to make back in 2011.
15 or 20 years ago on this forum, there used to be topics where someone would try to get people in agreement as to what should be on a single-board computer to share the NRE and do a group order. Now the prices are low enough that anyone can do their own (which is good, because agreement was never reached).
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I thought I read somewhere that PCBWAY, JLCPCB, and few other names were one-in-the-same company. I don't remember where I saw that conversation, and it may be false.
It could be that they, like DirtyPCBs, use a variety of board houses, and they which one they send your design to depends on how busy each one is at the moment and what their strengths are compared to your requirements.
ElEctric_EyE, I know we've gotten a little OT, but you can pull it back of course. I would do via tenting with PCB Express (now part of Sunstone), but it sounds like you're saying ExpressPCB still requires you to use their software rather than using whatever you want and sending gerber and Excellon files.