In the Resistors_SMD library, there is a R_603 as well as a R_603_HandSoldering footprint. I checked and these footprints are two different sizes… and one has square pads and the other rectangular pads and at different spacings. Now it it obvious that reflow soldering is different than hand soldering. However, isn’t a 603 SMD resistor a standard footprint? Having different libraries implies that I can actually purchase two different sized SMD 603 resistors? When I search Digikey, there is only one case/package size of 603. They do not distinguish a hand solder “size”. Could someone clarify? Thanks!
Did you check how a real 0603 fits over both ? I would expect what you describe to still ‘fit’ the part ok ?
Personally I’ve never had problems with standard sizes, but I have modified smaller footprints to allow a trace under the package, and a longer toe can assist heating the copper with a real world soldering iron radius tip.
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Compare the standard 0603 with the IPC Nominal footprint from https://github.com/cpavlina/kicad-pcblib and you will see that the KiCad version has smaller and wider spaced pads, (to squeeze two tracks through?).
In my opinion the hand solder version goes too far and I plan to use the IPC Nominal in my next project
Larger pads might help with hand soldering, but I never had a problem with the 0603 footprints in the “old” KiCad. I’ve encountered problems with parts that only have pads under the package, QFNs and crystals. For caps and resistors the tinned ends wick the solder easily enough, although the standard SMD pads in KiCad could be a little bigger for easier hand soldering, and the “HandSoldering” versions are really too big.
There are no SMD components designed specially for hand soldering - they are all designed for mass production process.