There are basically two options open to you if you are hand spraying with a solvent based conformal coating.

1. Use a pealable masking compound, probably latex based. This is applied allowed to dry and you then coat over the masking.
   
   The pealable mask is later peeled off exposing the contact pads.
2. Masking dots, these are basically small stickers provided on a roll that are simply stuck over the pad before coating therefore eliminating the drying time of a pealable mask. It is important to use silicone free masking dots as the silicone can cause de wetting of the coating.

In both cases above it is a good idea to remove the pealable mask or dot soon after the coating is dry to prevent tearing the coating during removal.

One more good tip for clean removal of masking is to use a little thinner on a cotton bud to dampen the area at the edge of the masking. This will soften the coating eliminating tears.

For masking contact pads, there are two widely used solutions. Firstly, the application of a liquid peelable masking material, which can be either air/heat dried, or UV cured.

These materials are designed to peel easily from the contacts after coating, through the conformal coating layer, thus removing the coating from the keep-out area.

The second method is the use of a tape... polyester or Kapton tape are common, and the process is largely the same. Key thing to note, ensure the adhesive in the tape is non-silicone based, or else you may encounter dewetting and lack of coating adhesion.

For both methods, it is usually best to demask as soon as the coating is dry to the touch. The drier or more cured the coating, the harder it can be to remove the masking material through the coating and the more likely you are to damage the coating, requiring touch-up to give the desired cosmetic finish.

Depending upon the volumes of boards you have to coat, a selective robot may be a better long-term choice, thereby largely eliminating the need to mask.

Hope this helps.

Conformal coating is more an art than science, in its application. Even the automated spray systems require some technique to control the wetting properties.

Assuming you are using Acrylic, you might use some simple process changes with hand application.

Your contact pads are ENIG or Conductive Rubber?

If they are ENIG, you may want to remove solder resist in an area that matches or exceeds your masking tape.

If your conformal coating is migrating under masking, you can also apply silkscreen print to hinder the capillary action of the conformal coating under the adhesive tape. This is a good technique to help control wetting properties.

If you are applying this coating or any coating with a spray method, we recommend a laminar flow to outline the attribute or area on the boad, then follow it with a spray which is boarding the laminar flowed area.

This method will help the first applied coating to wick toward the second pattern applied. This is effective especially around components which are not sealed or have tendency to collect coating where you don't want it.

Masking is still the best option. But the masking can also be done with precision placement of a UV cured lacquer over the contact pads. The cured lacquer will have a surface tension different from the conformal coating, and thereby will not bond with the conformal coating as it is applied.

Think of it as precise location of "incompatible surfaces" ... sort of like lithographic printing processes.

You will either spend time masking pads or you will need to spend money on capitol equipment, that can coat around the pads. Its a simple ROI calculation.

We make equipment from bench top systems to in line conformal coating equipment and would be interested to help you.