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I am writing a manufacturing specification for our contract manufacturing.

So far, the smallest component on our PCB is a 0402 resistor, however, I would like to specify a process that will be capable of handling our future requirements.

A design requirement we have is the reduction of the PCB layout size. As such it might be better to go to 0201 resistors in the revision.

Does anyone know the differences between 0402 and 0201 footprint resistors? Is it purely power and price or are there other things worth considering?

edit: interesting frequency response relation documented here: http://www.vishay.com/docs/60107/freqresp.pdf "reduction in parasitic impedance for smaller cases sizes"

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  • \$\begingroup\$ Top of head: Spark voltage and creep distance at the least. \$\endgroup\$ – Asmyldof Jul 24 '15 at 10:30
  • \$\begingroup\$ Why only resistors, why not capacitors too. Also look at [choosing surface mount resistor/capacitors]( electronics.stackexchange.com/questions/12409/…) \$\endgroup\$ – Mahendra Gunawardena Jul 24 '15 at 10:35
  • \$\begingroup\$ Manufacturing failure rate might be of importance \$\endgroup\$ – Scott Seidman Jul 24 '15 at 10:45
  • \$\begingroup\$ @MahendraGunawardena hmm good link but no reference to 0201 "You do have to do some due diligence before choosing parts, namely: are the parts rated for the expected power dissipation? are the parts rated for the expected voltage? is the design manufacturable? Some generalizations: 1206 resistors: 0.25W maximum dissipation, 200V maximum 0805 resistors: 0.125W maximum dissipation, 150V maximum 0603 resistors: 100mW maximum dissipation, 75V maximum 0402 resistors: 62.5mW maximum dissipation, 50V maximum \$\endgroup\$ – Quantum4 Jul 24 '15 at 10:45
  • \$\begingroup\$ Availability including stocked quantities of higher values and special types (high precision, pulse rated, sulphur resistant, non-magnetic) may be more limited as you go down in size. \$\endgroup\$ – Spehro Pefhany Jul 24 '15 at 11:50
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0201 pros - smaller foot print and as a result smaller PCB.

0201 cons - not all P&P machines can do these tiny parts so you will have to find an assembly service provider that can handle such small parts and has the right machines for the job. He would probebly charge you extra too.

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Pay attention, even in cell phones not always 0201 is used. It's still something you should avoid if you can.

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