- 0.1mm is too tight toward the high end if you’re designing for automatic insertion of parts with bent leads.
- Generalmente 0.8mm is okay for most leads except fat diode leads, for which you can use 1.0mm.
- Usually 1.3mm holes are specified for 1mm pins (for example on terminal block datasheets).
- Sometimes 1.5mm which is really, really loose.
If the leads are flat or square rather than round, you can go a bit tighter on the diagonal dimension, assuming a round hole. For really flat leads, it’s better to specify a slot.
If you’re using some kind of special part, such as a staked connector or press-fit part, pay attention to the tolerances.
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