Homebrew PCBs

0402 is my standard size. Especially for decoupling caps, but also resistors.  I use 0603 or larger if I need the extra power dissipation. 

I have done a few 0201's as well, but those are a little trickier. Sometimes just the static buildup on the vacuum pickup tip makes it hard to get an 0201 to detach and stick to the solder paste. 0201's have a tendency to tombstone more often as well.

There are now 01005's out there, but I have not had a chance to try them yet.

I figure as long as I have the resolution to make the boards I could go to the diffraction limit of my microscope. :)



--- In Homebrew_PCBs@yahoogroups.com, Adam Seychell <a_seychell@...> wrote:
>
> Following the recent posts on BGAs, I'm curious what people consider the 
> lower size limit for SMD to when doing home brew PCBs and projects. I 
> used to use 0805 but found soldering 0603 parts wasn't that much more 
> difficult, and so its my preferred choice for a new project. I 
> experimenting with some 0402 on scrap motherboards and found it way to 
> tedious to be practical. A big problem I see with 0402 is an inability 
> to run a trace between pads.
> 
> I found the no-lead chip scale packages (QFN) are somewhat more 
> difficult to solder than corresponding leaded TQFP of the same pin 
> pitch. Without reflow soldering, the pins of a QFN rely in wicking of 
> solder applied from soldering iron tip located on the pad just external 
> to the package. Its difficult to know if solder as wicked between pad 
> and pin.
>