One of my customers has a problem along the same lines as the original 
question regarding plugged vias.  
They have vias in some of the surface mount pads on two sided boards with very 
dense smt on one side.
These are not multlayer boards.  Its basic .062 FR4 and costs cannot go up.  
Vias are .012 and the solder joint is naturally always bad and has to be 
touched up.  Space is an issue and redesign will probably mean more is needed. 
Dozens of part numbers are involved.

Leonard Johnson
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