Over the past thirty years, surface-mount technology, or SMT, has become established as the industry standard way of constructing electronic circuits. While traditional through-hole components are still around, many important components are only available in SMT packaging of one form or another.
SMDs — surface mount devices — make things harder for electronics hobbyists and enthusiasts, being much smaller and harder to work with by hand, and less amenable to prototyping on a breadboard. But they’re by no means impossible to work with, and soldering them by hand is a skill that many people can and do learn.
A few weeks ago, I decided to do likewise, so I ordered an SMD soldering practice kit on Amazon.
Honey, I shrunk the resistors
The practice kit came with a variety of components, including resistors and capacitors in four different sizes. To give you an idea of how small they are, here’s a picture of four resistors, one in each size, and a 44-pin quad flat pack (QFP) microcontroller, next to a couple of classical components, a fine-pointed soldering iron tip, and a ruler for scale.

The smallest of these four resistors is an 0402 size, just one millimetre long and half a millimetre wide. The other three above it, in increasing size, are 0603 (1.6 x 0.8 mm), 0805 (2.0 x 1.2 mm) and 1206 (3.0 x 1.5 mm).
I started with the larger ones and worked down. I was able to get fairly consistent results with the 1206 and 0805 size components without too much trouble. It helped that I had had the foresight to buy a set of fine-tipped electronics tweezers at the same time. The 0603 resistors were a bit trickier and it occasionally took two or three attempts to position them correctly, but on the whole I managed them without too much problem. The 0402 resistors were a bit of a lottery though. About a third of the time they would develop a mind of their own, sticking up in the air instead of lying flat (an effect known as tombstoning), pointing off to the side instead of across the gap between the pads, getting both ends soldered to the same pad, or even ending up stuck to the tip of the iron. They would almost always get stuck to the tweezers that I was using to pick them up, and on more than one occasion I ended up singeing the PCB because I’d taken too many attempts to get it right.
Which size should I use in my own projects?
Following my success with the practice kit, I’m designing my first SMD-based project in KiCad, and one of the things I’m having to do for this is to decide what size of components I should use for it. This is likely to influence my subsequent projects, because I’ll be buying them in a sample pack or two, such as this one or this one, and it makes sense to use the same size on going forward rather than splashing out unnecessarily on a second pack. But these packs contain thousands of components, so they’re likely to keep me going through dozens of projects.
I decided to ask on /r/AskElectronics to find out what everyone else does and whether there was one particular size that predominates. The discussion has grown to 34 comments.
The general consensus seems to be split between 0805 and 0603 sizes. One or two people preferred 1206 because it’s easier to work with, but most people seemed to think that by the time you get to that size, you’re starting to see diminishing returns in that respect and the extra size isn’t worth it.
There’s also a general consensus that 0402 makes life unnecessarily difficult for yourself unless you have some serious space constraints. This comment summed it up nicely:
0805 for hand soldering. Can i do 0402. Yes. Can i do qfn. Yes. Do i want to suffer. No. Just pick the biggest and simplest package if you can for hobby projects.
However there is more to size than just preference and mechanical constrains. Parasitic inductance, power rating, reliablity, failure modes, available values for capacitors, voltage rating etc… all differs based on size. But it is 0805 that has more options but relatively small. But sometimes you need bigger.
On the other hand, another commenter said that I should go for 0402 anyway, because it helps you to flaunt sharpen up your skills:
Are you mad? If you managed 0402 alright, then use your abilities. If you can benefit from downsizing a pcb, go for it. If size doesn’t matter go for 0603, they don’t get lost as easy. You’re the man now dog.
I’m not sure I agree with this sentiment. Choosing the harder option might make you look good from a geek credit perspective, but “harder” means harder to get right, easier to get wrong, harder to see that you’ve got it wrong, and harder to fix when it does go wrong. When a component has ended up sticking to the tip of your soldering iron, even if it survives the experience its performance and structural integrity is going to be weakened, it may drift off-spec, and failure rates will be higher. This isn’t software, where you can just refactor if something doesn’t work out (or get your favourite coding LLM to do so for you); worst case, a mistake can ruin your entire circuit board and force you to start over again.
At the moment, I’m leaning towards 0805, though I haven’t finalised my decision yet. The size difference from 0603 isn’t big enough to be a deal-breaker, but it is noticeably easier to work with, and it gives a bit more in the way of power capacity. It’s only worth going smaller if you have specific use cases, but in general it seems like that option is the best “all rounder.”














