Hi Neil,
3 microns of gold is a lot of gold. As mentioned earlier, 1 to 1.25 microns
of low stress nickel worked for the BetaPhase connectors which use flex in
their construction. 1 micron of gold should be enough depending on how many
insertions are expected.
The plating appears very bright and brighteners have been shown to be a
potential indicator create stress.
Werner's comments on the copper are important to follow up on.
What is the purpose of the metal nub in the trace that is partially cover
coated?
Though it is provided with a radius in the transition is could be acting as
stress riser as there is not a counter point / balancing feature on the other
side.
Only the outer trace fails, yes?
Good luck,
Joe
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