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Clever! I'm thinking a similar design with a range of hole sizes and wider borders could be a handy generic tool - might have to design and order one next time I'm making boards with QFNs.

Does anyone here know what the smallest practical hole size is in acrylic?

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My gut feeling is 0603 might still work but probably not reliable, 0402 tends to get stuck to everything by static attraction so very doubtful in acrylic.

Not to mention ESD issues from rubbing all your components across acrylic.

for small stuff the real limit may be "how round are the corners"

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