I have designed a power supply card using V7805-2000. Copper thickness is 70 microns, board size is 5 cm × 5 cm.
When this underwent vibration test the regulator came off, broken into two pieces(regulator leads are in the holes).
I have used 40 mils drill size, 130 X 70 regular pad size. 135 X 75 mils anti pad, thermal pad and solder mask top and bottom.
In the above image, you can see that there is an 0.5 mm notch from the surface of the regulator.
I have used vias on one side, where this notch gets mounted/placed on the PCB. Hence the regulator moves/shakes slightly when moved with a hand after assembling.
Even there are copper shapes on one side of the notch.
Is this might be one of the reasons why the regulator broke?