Hi Doug,
You are really beyond interpreting IPC-A-610, since it is the PWB design
("The engineer designed an ineffective thermal relief pad to connect a leaded
component's ground through-hole to the ground plane" & "Our design uses the
ground plains as thermal/heatsinks" & "the component's ground lead, which
causing all the problems, is connected directly to the steal shielding
measuring 2x2x1"), not the suppliers fault ("I need assistance with defending
the supplier").
The question you really need to answer is: Will this assembly be reliable or
not.
For this you need to consider the application operation and use enviroonment,
and other design details, such as how much stress relief do the component
leads provide, how thick is the PWB (12 layers ~2.1 mm), what is the PWB
material (CTE(z), Tg), etc.
If the conclusion is that what you have is not reliable, your only possible
recourse is to pay for manual rework in an attempt to fill the PTHs.

Werner Engelmaier
Engelmaier Associates, L.C.
Electronic Packaging, Interconnection and Reliability Consulting
7 Jasmine Run
Ormond Beach, FL  32174  USA
Phone: 904-437-8747, Fax: 904-437-8737
E-mail: [log in to unmask], Website: www.engelmaier.com

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