Gerber Via Size Issue

V

vasy_skral

I sent this gerbers to the manufacturer and I got this message from the manufacturer: "There are holes with a size of 0.2 mm and a diameter of 0.3 mm in your file. To ensure the quality of your order, the 4-Wire Kelvin Test is mandatory. You have to pay an additional cost for this service. Or if you can modify the hole size/diameter to 0.2/0.45mm, we will not need such a test."
Can you find what via is 0.3mm?

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flux

The current PCB now uses 0.30 mm drill / 0.60 mm via diameter, so the manufacturer’s 0.20/0.30 mm vias are from the submitted Gerber version, likely affecting many routed vias rather than one via.
I need Agent mode to extract the ZIP’s Excellon drill files and report the exact count and coordinates of every 0.20 mm drill with a 0.30 mm copper diameter. Click the button to continue.
Continue in Agent Mode

flux

I’ll inspect the submitted drill and copper files, then map every 0.20 mm drill using a 0.30 mm via diameter back to its coordinates and net where possible.

flux

Found them: the 12 problematic 0.20 mm drill / 0.30 mm diameter holes are in the ESP1 (ESP32-WROVER-E) exposed ground pad.
  • Net: GND
  • Footprint pad: ESP1 – EXP
  • Pattern: 12 thermal/stitching holes under the module
  • Classification: component plated holes, not ordinary routing vias
  • Confidence: very high; confirmed through the drill file and IPC-D-356 netlist
The fix is to change those ESP1 exposed-pad holes to 0.20 mm drill / 0.45 mm copper diameter, then regenerate the Gerbers.
Fix ESP1 thermal vias
Verify footprint clearance
Regenerate manufacturing files
Check all small holes
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ESP32 x86 PC