today my pcb maker told me they can't get all components on the board. I was wondering if some might have suggestions for improvement. Attached the schematics and pcb design. the part outside the white lines does not fit on the board. pcb size is 15x8mm. Total available space for pcba is 15x8x6mm. i appreciate your help.
Either one of two things has to happen here.
1. The board size needs to increase or
2. The component count needs to decrease.
Simple as that.
A lot of the microcontrollers today have an internal RC oscillator that can be used in place of an external crystal / oscillator. You may want to look into using the internal clock source and verify it can provide the stability required to support the USB comm. Also, I think you can remove the diode in the reset line or at least go with a much smaller part. Making these two mods will free up some board space, but I stiil don't think you will get everything in the given area.
Another thing, look into the actual size of the parts vs the silk screen around them. A lot of room is being taken up by the silkscreen. You'll notice that a lot of the high density boards eliminate silk from the design which allows for closer placement (within DFM constraints). But your board design provider should be aware of all of this.........
If you have the room for another pcb in the enclosure, that might work well. Maybe put the USB conn on its own board and that would free up a lot of room for the micro and LEDs on another board.
It usually never works out well when the mechanical design is done before the electrical / board design. But I run into this all the time.............