If you run out of ideas working with the drillers, check into the material
itself. We had this problem a couple years ago and after exhaustive searches
and experiments in the plating areas we finally got the manufacturer to admit
that they released material that was not cured properly. Although it took
months for the answer, during which time we were replacing alot of boards, we
did at least get an answer! I can't stand it when a problem shows up and then
goes away before a remedy is found :-)

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