nRF 52840 PCB design

[Maksim]

I am designing a pcb just the nRF 52840 MCU. The design of the PCB is based on the reference design from Nordic. 
When ordering the PCB I came across a problem that the vias under the MCU are too small and too close together to be able to order the PCB for a 
normal price. 
I have been informed that the technique with which this can be done properly is a laser technique that companies like Eurocircuits.com do not have. 
This means that I cannot realize the design before this problem can be solved. The chip is constructed in such a way that the vias must be so small. 
Is there an alternative where I can order the PCB for a normal price or are there cheaper design options that reduce the costs?

[wpaul]

awneil said:

Have you considered using a module?

I was going to suggest this too, but this depends on two things:

1) Will a module physically fit the desired PCB design (I know some people want to build really tiny boards)

2) Will the added cost be a problem

You can buy the nRF52840 IC in large quantities for about $4 each, but for the Rigado BMD-340 it's more like $8. However with the BMD-340 you also get a built-in BLE antenna and an integrated 32MHz crystal. Whether that balances things out or not depends on the application design, I guess.

My friend and I elected to go with the Rigado module for our project primarily to avoid (we hope) potential problems with the nRF52840 footprint. We were able to do a large order to help reduce the per-unit cost. It was still annoying to route everything, but not as bad as it might have been with the IC itself.

-Bill

[awneil]

Yes, the per-unit cost of a module is higher.

But the design cost of getting a PCB right and fully qualified is extremely high; as the OP has found, it is not a trivial exercise - and that's before even getting onto the RF parts!

It's generally reckoned that a a bare-chip design is unlikely to be viable unless you're looking at volumes over many tens of thousands.

https://www.silabs.com/whitepapers/six-hidden-costs-in-a-99-cent-wireless-soc

https://devzone.nordicsemi.com/f/nordic-q-a/48284/nrf52832-wlcsp-ciaa-rf-do-not-work/191537#191537

https://devzone.nordicsemi.com/f/nordic-q-a/48816/regarding-the-schematics-of-the-nrf52/193876#193876