[MartijnBraam]

I just quickly tried to fit the whole rp2040+ethernet phy in the WIZ850io formfactor (mainly because I already used that module in some projects before) and have not yet been able to make it fit without using the more expensive jlcpcb features like burried vias. It would be very cool to have though since the W5500 really needs an update.

[bangaladore]

I'm unable to respond to your deeper comment, but I don't see any issue at all with this. Your concern about the vias doesn't make sense as you just tent the vias anywhere you are concerned about shorts. I'm 100% certain you can fit both chips, all passives, etc, in this formfactor. If the flash size is a concern, RP2350 (the new version of the 2040) has integrated flash for some of their packages. Or just use a chip scale (or similar) flash instead of the one normally used on RP2040 designs.

[bangaladore]

A 4-layer in that form factor should be pretty doable with no fancy features like blind vias. The RP2040 and W5500 are the same size, and ethernet PHYs can be found in about 3x3mm or even smaller. There should be about 20x25mm of usable space in that module form factor (even conservatively, like 18x23).

I don't have the time to give it a shot myself, but I could try to help if needed.

[MartijnBraam]

The issue is more the space needed by all the passives, the crystal, the massive flash chip. I can just about make it fit but now I have the issue that the phy needs some vias to the center pad for gnd but that's always right at the point where my ethernet jack is on the other side.