Clearly flux and process set-up are influencing factors, but once all available
adjustments have been made, we too found that the biggest improvement
available was to specify matt finish soldermasks. The glossier finishes
apparently soften slightly at soldering temperatures and allow solder balls to
adhere to the surface - the rougher surface texture of a matt finish
discourages the balls from staying. We also found matt finish masks helped
shift stubborn solder bridges caused by PCB design. The "extra-matte" version
of the Coates Imagecure resist gave us the best results, but no doubt others
are equally good.
<http://www.sunchemical.com/products/electronic_materials/imagecure>
<http://www.axoncircuit.com/downloads/Coates.pdf>
Nigel
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