> Could you replace the discrete darlingtons with an array?
> Might be easier if you didn't have to solder each individual
> transistor

That's what the Allegro ULN200x, 25xx and 28xx series are. As I
noted in a previous post, the problem I found with arrays isn't so
much with ICs but with the PCB under them. To prevent this fault
recurring I attach heatsink fins to them, and this works well.

Discrete transistor designs don't have this problem nearly so
badly and Darlingtons in isolated tab packages are quite easy to
get hold of if the transistors are to be mounted on a case panel or
common heatsink

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