So why is it that high-current BJT transistors recommended for switching (low Vce(sat)) typically have a low-ish gain of 100, while a common 100mA BC547b is about 250.
A safe approach for mass-production?
Hobby-dudes can (should) measure Vce(sat) and can get away, if needed, with maybe 2% base current. I would stick with 5% though.
Leo..