Rick...
Another place to look is at the phototooling. Most people, I assume,
supply Gerber type output for the supplier. However, if not, the phototooling
would be a chief culprit with handling imperfections. If Gerber is supplied,
then apperature problems can be a cause of error. Of course, in the fabrication
cycle the whole world opens up with a mutitude of fab tolerences coming into
play. IMO, you must talk with you fabricator to ensure that he can meet your
end product requirements and that you really need those requirements.
If your design requires them and your supplier cann't meet them --
start looking for a new supplier. Hope this helps.
Bob Vanech
[log in to unmask]