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Understanding Finished Slot Size

Tolerances When Manufacturing PCB

When designing and manufacturing printed circuit boards (PCBs), one

important design consideration is slot tolerances. Slots refer to the gaps or

openings in the PCB, such as between pads, traces, or ground planes, that

allow clearance for components or other features. The size and precision of

these slots impact the fit and performance of the PCB.

Specifically, the finished slot size tolerance indicates the allowable variation

in the final manufactured size of slots compared to the designed dimension.

Controlling slot tolerances is crucial for ensuring components properly fit into

cutouts and openings without interference or excess slop. Tighter tolerances

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lead to more precise and reliable PCBs, while looser tolerances reduce

manufacturing costs.

This article provides an in-depth examination of common PCB slot size

tolerances, factors impacting tolerances, and how to appropriately specify slot

tolerances when designing and ordering custom PCBs.

Overview of Common PCB Slot Tolerances

Slot PCB

Standard finished slot size tolerances for PCB manufacturing typically range

from ±0.075mm to ±0.250mm depending on the slot size. The table below

summarizes common IPC specifications for PCB slot tolerances:

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However, many PCB manufacturers can offer tighter tolerances, down to

±0.025mm, for critical applications requiring precision slots at added cost.

These tolerance ranges indicate the total potential variation between the

minimum and maximum finished slot sizes. For example, a designed 50mm

long slot would have an actual manufactured length between 49.925mm and

50.075mm with a ±0.075mm tolerance.

What Impacts Slot Size Tolerances

PCB slot TOLERANCES

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Several variables influence the precision of slot fabrication and the final

achievable tolerances:

PCB Materials – The base material’s mechanical properties and stability affect

dimensional accuracy. More stable and rigid materials like FR-4 can improve

slot precision.

Board Thickness – Thicker boards tend to enable tighter tolerances due to

added rigidity and stability. Thin flexible boards are prone to greater variability.

Slot Size – Smaller slots can typically be held to tighter absolute tolerances.

However, proportionally wider tolerances may be needed for larger slots.

Manufacturing Process – The particular methods, equipment, tooling, and

quality control used impacts tolerances. More automated processes tend to

improve precision and repeatability.

Testing and Metrology – Measurements after fabrication using calibrated

metrology tools ensures slots stay within specified tolerances. This testing adds

cost.

Functionality – Slots designed for tighter clearance around mating

components require precision, while large generic cutouts permit looser

tolerances.

Role of Annular Rings

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Slot Design

Annular rings around the pads or traces exposed within slots also affect

tolerance requirements. Larger annular rings provide more margin against

potential slot size variability. If slots shrink below their minimum limit, small

annular rings could fully disappear. This would cause short circuits or open

circuits, damaging board functionality.

Therefore, appropriately sized annular rings must be maintained relative to

minimum slot sizes and tolerances to ensure reliability despite allowable

fabrication variations. Annular ring design rules are defined in IPC-2221

standards based on voltage levels.

Benefits of Tighter Slot Tolerances

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PCB Hole Tolerances

Specifying tighter finished slot size tolerances where possible provides

multiple benefits:

 Allows less annular ring margin required around traces and pads due to less slot size
variability, saving space.
 Prevents shorts, opens, and clearance issues by avoiding excess slot expansion or
shrinkage.
 Ensures proper electrical isolation between features exposed in slots.
 Enables accurate component mating and fit without interference or excess play.

The tradeoff is increased PCB fabrication time and cost to meet tighter

tolerance requirements.

Best Practices for Specifying PCB Slot Tolerances

Follow these guidelines when defining slot size tolerances for your PCB layout:

Research Manufacturer Capabilities

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Contact potential PCB production partners to understand their specific slot

tolerance capabilities based on materials, layer counts, testing methods,

volumes, etc. before setting tolerance expectations.

Perform Tolerance Analysis

Analyze minimum annular ring requirements and component mating

clearances to derive suitable overall slot tolerances for each unique location.

Document Tolerances in Drawings

Clearly record finished slot size dimensions along with +/- bilateral tolerances

on PCB fabrication drawings to eliminate confusion.

Apply Tighter Tolerances Judiciously

Balance functionality against cost by only specifying tighter tolerances where

absolutely necessary, such as small slots with exposed traces/pads or precise

component fits. Use standard tolerances otherwise.

Employ Slot Patterns Strategically

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When slots mimic repetitive patterns, as along board edges, use consistent

lengths and positions to leverage dimensional stability from slot-to-slot rather

than cumulative variability.

By thoughtfully accounting for slot size tolerances during PCB design and

fabrication specification, both functional reliability and manufacturing

efficiency can be optimized.

Specifying PCB Slot Tolerances with IPC Standards

Industry standards published by the Association Connecting Electronics

Industries (IPC) in IPC-2221B provide definitive design guidelines and

requirements for PCB tolerances. These standards aim to balance precision

against cost based on application classes.

Several tables in IPC-2221B Section 7.3 define slot tolerances for common PCB

types, which serve as the basis for the tolerance ranges summarized earlier.

However, IPC notes tolerances should be defined between designer and

manufacturer based on specific needs.

When preparing fabrication drawings and models, reference these IPC tables

but also explicitly specify bilateral +/- finished slot size tolerances separately as

needed per application. Carefully developed custom tolerances override

generic standards.

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Impact of Panel and Board Size on Slot Tolerances

pcb slot types

During PCB mass production, multiple small individual PCBs are arranged on

large panel sheets for batch processing efficiency. However, panel and board

sizes also influence achievable slot fabrication tolerances.

Larger panels tend to enable tighter tolerances as dimensional stability

improves across the full panel area during processing. Registration between

steps benefits from a common large reference frame.

But upon separating into smaller boards, stability is reduced as individual PCBs

can slightly shrink/grow uniquely. More handling and precision routing/cutting

also introduces variability.

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Smaller boards lack the stability of large panels during fabrication. But they

undergo less secondary processing once completed. So cumulative tolerance

effects are minimized, albeit at higher cost from lower batch efficiency.

Therefore, both panel and final board size should factor into slot tolerance

specifications. Generally, larger panel sizes help meet tighter tolerances, but

tolerances may still need to be opened up for very small boards.

Role of Component Libraries in Accounting for Tolerances

To guarantee proper function after assembly, component footprint sizes used

for PCB population design must account for potential variations of slot

tolerances as well as component tolerances.

Standard component libraries provide recommended footprint dimensions at

nominal target values. But they may not consider real-world tolerance ranges.

So when creating footprints referenced to finished slots, grow/shrink

dimensions by at least the bilateral sum of both slot and component tolerance

extremes to ensure fit within worst-case tolerance stack-up conditions per

IPC-7351C guidelines.

How Testing & Inspection Validates Slot Size Tolerances

Verification of slot sizes against specified tolerances commonly involves

several testing methods throughout the PCB production process:

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Optical Inspection

Automated optical inspection (AOI) systems image boards to check slot

locations and dimensions. Precision measurement tools confirm sizes stay

within tolerance limits. This method offers rapid whole-board inspection.

Laser/Vision Measurement

Precision laser micrometers and machine vision systems provide accurate

non-contact measurements of select critical slots on sampled boards from a

production batch. Used for process control and audit purposes.

Manual Inspection

For quick validation checks, experienced inspectors manually measure key slots

across boards using calibrated metal gauges according to IPC-A-630.

Statistical sampling saves time.

Electronic Testing

Testing boards electronically with probing fixtures checks for electrical

clearance/isolation across critical slots like traces or ground planes. Confirms

no shorts or leakage paths.

Component Testing

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Physically attempting to assemble components into aligned slots verifies fit

and tolerances. Binding, interference, or excessive play indicates issues.

When specified slot tolerances are not consistently met, process adjustments

can be made. If tolerances are too tight to achieve, they may need to be

opened up.

Accounting for Tolerances in Electrical Calculations

For slots providing electrical isolation between traces, planes, or pads at

different potentials, the following worst-case calculations should be

performed:

Trace-to-Trace Isolation Over Slots

Minimum Required Dielectric Withstand Voltage:

Vwdmin = Vmax + (spacing * CTI)

Where:

Vmax = Maximum applied voltage

spacing = minimum slot width under tolerance

CTI = Comparative Tracking Index based on board material

This predicts if spacing allows required isolation voltage levels despite

tolerance variability.

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Plane-to-Plane Isolation Over Slots

Minimum Leakage Distance:

Ldmin = (Vmax / Vbr) + slot tolerance

Where:

Ldmin = Minimum leakage distance under tolerance

Vbr = Dielectric breakdown voltage

This checks if the slot size and material withstand voltage still safely isolate

planes.

Example PCB Design Studies on Slot Tolerance Impact

To illustrate the significant effect slot size tolerances have on PCB reliability

and performance, two example studies are summarized below:

Broken Ground Plane Example

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 Minimum slot tolerance for safe isolation per IPC-2221B: ±0.150mm

 Actual fabricated slot size: 24.2mm (exceeds max. limit by 0.05mm)
 Result: Internal ground plane was fully isolated causing circuit failure. Tighter tolerances
or larger slot required.

Component Placement Study

 Component library recommended margin: +0.1mm

 Actual manufactured slot allowed looser component fits
 Result: Insufficient tolerances caused cracked QFP joints and opens during vibration
testing.

As demonstrated in both examples, properly accounting for PCB slot size

variability is critical to prevent functional issues despite passing nominal design

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rules. Tighter tolerances and component footprint adjustments could have

prevented problems.

Frequently Asked Questions About PCB Slot Tolerances

What are the main benefits of precisely controlling PCB slot

tolerances?

Stringently managing slot tolerances enables reliable electrical isolation

between traces/pads, ensures components properly fit, prevents shorts/opens,

reduces need for annular ring margins, and improves overall board quality.

How can PCB manufacturers typically achieve tight tolerances

down to ±0.025mm?

Combinations of optimized robotic machinery, strict process control, precision

measurement equipment, thin dielectric layers, and statistical feedback allow

capturing boards with slots meeting much tighter distributions despite

inherent material/mechanical variabilities.

Should slot tolerance requirements change depending on board

complexity?

Generally yes. Simpler low-layer count boards permit opening slot tolerances

slightly without jeopardizing function. But complex designs with tight

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clearances require maintaining uniformly tight control of slot variances

regardless of location.

Is it advisable to intentionally adjust component footprint sizes

to account for slot tolerance variability?

Absolutely. Widening pad/trace spacings referencing slots helps ensure proper

isolation and fits despite cumulative effects of slot and component production

variability per IPC-7351C recommendations.

How can PCB fabricators help designers determine appropriate

slot tolerances?

Manufacturers can provide their achievable tolerance capabilities for different

layer counts, materials, and slot sizes. Their recommendations based on

experience can define application-specific bilateral tolerances personalized for

your board rather than just generic IPC tables.

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