My personal experience with .093 thick boards on
standard FR4 material was very similar to yours.
After a LOT of lost dollars due to bad boards, we
switched over to a higher Tg material and the problem
went away. It has since been proven I do believe that
a Tg of 150 - 180 is absolutely required on thick boards.'
This of course also depends on the number of heat
cycles the board needs to go thru.
Good luck and change over NOW. Also, try to get
the higher rated material for no additional cost from your
vendor.
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