0402 is my standard size. Especially for decoupling caps, but also resistors. I use 0603 or larger if I need the extra power dissipation.
I have done a few 0201's as well, but those are a little trickier. Sometimes just the static buildup on the vacuum pickup tip makes it hard to get an 0201 to detach and stick to the solder paste. 0201's have a tendency to tombstone more often as well.
There are now 01005's out there, but I have not had a chance to try them yet.
I figure as long as I have the resolution to make the boards I could go to the diffraction limit of my microscope. :)
--- In Homebrew_PCBs@yahoogroups.com, Adam Seychell <a_seychell@...> wrote:
>
> Following the recent posts on BGAs, I'm curious what people consider the
> lower size limit for SMD to when doing home brew PCBs and projects. I
> used to use 0805 but found soldering 0603 parts wasn't that much more
> difficult, and so its my preferred choice for a new project. I
> experimenting with some 0402 on scrap motherboards and found it way to
> tedious to be practical. A big problem I see with 0402 is an inability
> to run a trace between pads.
>
> I found the no-lead chip scale packages (QFN) are somewhat more
> difficult to solder than corresponding leaded TQFP of the same pin
> pitch. Without reflow soldering, the pins of a QFN rely in wicking of
> solder applied from soldering iron tip located on the pad just external
> to the package. Its difficult to know if solder as wicked between pad
> and pin.
>