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The zero ohm resistor only needs to be there in the first place if connection to chassis is optional - if it is mandatory then there's no need for the resistor to begin with. If the resistor is th...
#1: Initial revision
The zero ohm resistor only needs to be there in the first place if connection to chassis is optional - if it is mandatory then there's no need for the resistor to begin with. If the resistor is there, then indeed the proposed layout is bad, since the circular copper pour will get paste on it and also soak up a lot of heat if you try to solder a resistor there, no matter if done with pick & place + reflow or if soldered by hand. Furthermore if automatic optic inspection is used, it will probably find the wetting on the pad towards the screw to be fishy. I would guess this is a typical case where the average EE draws some layout while they don't have much clue about the soldering process in practice - it is quite common. Your solution is better since it prevents the solder from wetting onto the screw copper pour, and it also ought to act as thermal relief. Do note that a screw in whatever material (galvanized steel most likely), as well as the chassis connection (toothed washer? cable lug?) will likely have much higher resistance/inductance in comparison to the copper trace. For the best possible connection to chassis you would use a connector instead.
