PCB Manufacturing File & Drill Summary


The drill file is also commonly referred to as an NC (numerically controlled) drill file in the industry. Excellon is the preferred term used with our Sunstone services. The Excellon drill file defines hole locations and tool numbers (X & Y coordinates).


Preset Finish Drill Sizes (ValueProto Only)

 - Imperial sizes in inches (mils)

Your drill sizes (contained in your file) in these ranges will be converted to our pre-set finish hole sizes.

Your Tool Sizes Preset Finished Hole will be Tolerance ** Minimum Copper Pad Dimensions *** Minimum Copper Inner Layer Clearances
0.0160 - 0.0179 0.0140 +0.002/- 0.006 0.0310 0.0410
0.0180 - 0.0249 0.0200 +/- 0.004 0.0370 0.0450
0.025 - 0.0289 0.0250 +/- 0.004 0.0420 0.0500
0.0290 - 0.0319 0.0290 +/- 0.004 0.0460 0.0540
0.0320 - 0.0349 0.0330 +/- 0.004 0.0500 0.0580
0.0350 - 0.0380 0.0360 +/- 0.004 0.0530 0.0610
0.0381 - 0.0410 0.0405 +/- 0.004 0.0575 0.0655
0.0411 - 0.0449 0.0432 +/- 0.004 0.0602 0.0682
0.0450 - 0.0519 0.0460 +/- 0.004 0.0630 0.0710
0.0520 - 0.0599 0.0535 +/- 0.004 0.0705 0.0785
0.0600 - 0.0659 0.0610 +/- 0.004 0.0780 0.0860
0.0660 - 0.0759 0.0670 +/- 0.004 0.0840 0.0920
0.0760 - 0.0839 0.0800 +/- 0.004 0.0970 0.1050
0.0840 - 0.0899 0.0875 +/- 0.004 0.1045 0.1125
0.0900 - 0.0969 0.0935 +/- 0.004 0.1105 0.1185
0.0970 - 0.1059 0.1005 +/- 0.004 0.1175 0.1255
0.1060 - 0.1160 0.1100 +/- 0.004 0.1270 0.1350
0.1161 - 0.1329 0.1259 +/- 0.004 0.1429 0.1509
0.1330 - 0.1429 0.1410 +/- 0.004 0.1580 0.1660
0.1430 - 0.1529 0.1510 +/- 0.004 0.1680 0.1760
0.1530 - 0.1709 0.1670 +/- 0.004 0.1840 0.1920
0.1710 - 0.2019 0.1930 +/- 0.004 0.2100 0.2180
0.2020 - 10.000 0.2510 +/- 0.004 0.2680 0.2760

** Recommended minimum pad size guarantees through-hole electrical continuity.
*** Recommended minimum inner layer clearances prevent electrical shorts caused from through-holes connecting directly to ground plane.


PCB Drill File Requirements:

PCB Manufacturing Drill File General Requirements:

  • All PCB holes are plated through meaning, there will be solder in the PCB hole barrel.
  • Must be Excellon format
  • Must be ASCII text viewable. Please open with "Word" or "notepad" to verify a numeric list of X & Y coordinates. There should be no strange graphical characters.
  • PCB drill file should not contain "G01", "G54", or any reference to "D" codes when opened in a text editor. This indicates a Gerber format and is most likely a drill drawing rather than an NC file.
  • Properly formatted PCB drill files have sizes separated with "T" codes that indicate tool numbers. (T01, T02, etc)
  • A tool report with sizes is necessary if the sizes are not included in the drill file header.
  • For Slots or Cutouts: Fab Drawing, NC Drill File, or Gerber file is necessary to define slot/cutout size and/or location.

Service Restrictions:

  • All PCB holes are through hole from top to bottom layer of board.
  • We cannot guarantee Non-Plated through holes will be non-plated.
  • No blind or buried vias.
  • Maximum four slots OR cutouts for this service.
  • Please make sure there is space between holes, we require 0.010" from object edge to edge. Holes with <=0.006" between holes (after standard drill sizes are added), will be placed on hold until resolved. Sunstone reserves the right to modify the "perforation holes" (holes drilled to separate multipart designs) for best manufacturing efficiency and quality of end product.
  • Please limit your total number of PCB holes per board design to no more than 50 per sq-inch.
  • Sunstone cannot create the drill file from a gerber file, fabrication document or drawing.