How long is a piece of string... Double sided vs Second Board

I have been working on a project for a while now and today I came up against a problem where I screwed up, I missed a few very necessary components off my schematic.

The initial board outline is 157*80 and getting on for 800 components was already super tight, the missing components mean there is now no chance thee additions will fit.

So the string question…

I am on a 6 layer board and decided to look at double sided assembly,

My options seem to be double sided, larger board or a second board on top.

Are there any ‘rules of thumb’ on cost multiplication here, Ie is Double sided so expensive that a second board is cheaper?

I looked at jlcpcb etc but they want a gerber for a PCBA quote and I am not that far along…

I know the most cost effective solution is make it bigger but that comes with a whole host of other issues.

Thanks

Double sided will be cheaper than another board.

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I point out that often you will have footprints which lend themselves to placement on the back side. I recently did a board where I had only two components on the back side, only because it seemed to make the most sense. I wanted an RC lowpass to be connected relatively close to my fine pitch SMT IC, and I did not want to move other more-critically-placed footprints out of the way in order to do that.

The best example (was not quite my situation) that I can think of is where you have a 14 pin DIP IC, and you have one or two passive components connected between pin 3 and pin 10. Placement of those footprints on the backside allows reduction of track length as compared to the other options.

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So a bit of an update…

I noticed I had a lot of kicad and non kicad footprints with relatively large courtyards…


BLM21BB050SH1D

Currently researching why this may be for a same package size, so far the answer seems to be ‘because that is the way it was drawn’

If I can reduce courtyards and still meet DFM my problems be be reduced!

@BobZ I may still use the back side as you say, I have some 0201’s and 0402’s that could be better placed on the rear.

Thanks

You had better confirm with your manufacturer what the courtyard needs to be for tiny components.

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If you cut off the end of a piece of string, it’s length becomes infinite.
But if you accidentally cut off the start, you can’t find it anymore.

If this thread is about some other topic, then please adjust the title.

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The title was indicative of my question thought process but you are right of course, I have adjusted.

As it happens, I have now managed a redesign after being able to reduce courtyards to what JLC are still more than happy with. My next issue is copper balance but that’s a whole other story!

The learning Journey is fun, if a little daunting, this and other forums have been very good.

Cheers