Hi,
I’m trying to manufacture a bunch of LED sticks I designed, which need to have a profile that is as minimal as possible.
I’ve got a couple of single PCB sticks made at different PCB fabs which I then assembled by hand.I got the first iteration single boards from a PCB manufacturer, now I would like to get them assembled at the factory directly as I need around 700 of them.
For that I need to panelize the design and I was wondering what the best method for doing that is, particularly because of the unconventional shape of these boards and the board thickness which I would like to be 0.6mm. I already tried a panel design that uses breakway tabs to hold 10 sticks. The panels seem ok, but one of them has some weird bumps on the edges of the board, and when snapping out sticks from the panel there is still ugly residue from the mousebites attached to the sticks. This makes me hesitant to use this design and order the 700 assembled sticks.
That’s why I would like to ask some feedback on whether you think this is the best way of producing those sticks.
Is there a different way you would panelize this design? Have more or less sticks on a panel? 

Thanks!