Design of DNA arrays for very large-scale immobilized polymer synthesis (VLSIPS) (Fodor et al., 1991) seeks to minimize effects of unintended illumination during mask exposure steps. Hannenhalli et al. (2002) formulate this requirement as the Border Minimization Problem and give an algorithm for placement of probes at array sites under the assumption that the array synthesis is synchronous; i.e., nucleotides are synthesized in a periodic sequence (ACGT)(k) and every probe grows by exactly one nucleotide with every group of four masks. Drawing on the analogy with VLSI placement, in this paper we describe and experimentally validate the engineering of several scalable, high-quality placement heuristics for both synchronous and asynchronous DNA array design. We give empirical results on both randomly generated and industry test cases confirming the scalability and improved solution quality enjoyed by our methods. In general, our techniques improve on state-of-the-art industrial results by over 4% and surpass academically published results by up to 35%. Finally, we give lower bounds that offer insights into the amount of available further improvements.