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)

The drill sizes from your files (within these ranges) will be converted to the finished hole sizes indicated in the table below.

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 or silver 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 (PCBExpress only): Fab Drawing, NC Drill File, or Gerber file is necessary to define slot/cutout size and/or location.
    • To achieve a plated slot or cutout place the feature on the drill layer and include an outerlayer pad at least the size of the slot or cutout.  Maximum diameter for a plated feature is 0.250"
    • Non-plated slots or cutouts should be place on the outline layer.  No limit to size and shape. 

Service Restrictions:

  • All PCB holes are through hole from top to bottom layer of board.
  • Holes marked in files as non-plated through holes cannot be guaranteed to remain non-plated and may be plated.
  • No blind or buried vias.
  • Maximum four slots OR cutouts for this service.(All slots / cutouts larger than 0.250" diameter will be treated as a non-plated slot/cutout).
  • All holes > 0.250" will be non-plated.  If you need holes >0.25" plated, use the PCBpro Full-Feature Product.
  • 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.
  • For Quickturn service: Specified holes < 0.018" will be treated as vias, and drilled approximately the same size as specified. The smallest available bit is 0.0135". If your drill is smaller, it will be increased to this size.