I'm not sure if this has come up yet, but seeing the recent thread about someone "reconditioning" their Avalon and mentioning that the pads underneath each chip are lower than the soldermask, it got me thinking...
Would it be better to leave the whole bottom of the board without soldermask?
and...
What kind of surface finish do you plan on using? I believe any type of plating, such as gold, will leave a flat surface. But, HASL will not leave a flat surface, possibly degrading the thermal bond with the heatsink.
I don't think any of these issues are show stoppers but I was wondering what you guys thought.
Edit: Maybe these are not issues if you plan to use a thermal pad.
In order to keep the board reasonably cheap I won't be able to expose full copper on the bottom. This is because it would require using blind/buried vias so that inner layers don't short out on the bottom. This is why I went with exposed pads under each ASIC, and the tracks running from each ASIC have to clear the pad area to go via.
I'll likely just use HASL for the test boards so I can see how well that works, but I agree with it not being flat and it's likely that final boards would be ENIG (more costly)(depending on just how much trouble the HASL turns out to be). I'm really thinking there will be some 1x1cm pad under each ASIC, at least enough to account for the solder mask thickness.
I'm interested to know exactly what was meant by the person who took apart the Avalon and inspected the heat sink mating. I don't quite have a good image from the comment above. Did he mean it was just heat sink against mask except some exposed areas, or there was solder mask but thin pads that held the heat sink slightly off the mask, or something else?
edit: never mind - just went to see the photos. This makes me feel better...

(because if that works then almost anything will)