Gerber File Generation
A Gerber file is the standard file format used in PCB (Printed Circuit Board)
design to describe each layer of the board for manufacturing. It acts as the blueprint
your PCB manufacturer uses to create your board exactly as designed.
Purpose
Communicates precise layer-by-layer design data from PCB design software
(e.g., KiCad, Altium, Eagle) to the fabricator.
Defines where copper traces, pads, vias, silkscreen, and solder mask are
placed.
Includes drill data for holes (via Excellon files).
Contents of a Gerber File Set
Usually, a PCB manufacturer receives multiple Gerber files, one for each layer or
element:
Copper: Top (.GTL), Bottom (.GBL), and inner layers for multilayer boards (.GxL).
Solder Mask: Top (.GTS), Bottom (.GBS).
Silkscreen: Top (.GTO), Bottom (.GBO).
Mechanical/Outline: Board outline/route (.GKO or .GML).
Drill: Excellon drill file (.DRL) and optional drill map (.TXT/.PDF).
Why It’s Important
Universal standard – manufacturers worldwide accept Gerber format.
Ensures the exact physical representation of your PCB.
Without Gerber files, the PCB manufacturer cannot fabricate your board.
How They’re Generated
After designing a PCB in CAD software:
1. Open the Plot / CAM Processor tool.
2. Select Gerber format (RS-274X).
3. Export each layer as a separate file.
4. Also generate drill files.
5. Zip and send to the manufacturer.
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Standards
RS-274D (Legacy): Early Gerber variant; required a separate aperture wheel (D-
code) file. Ambiguity-prone and largely deprecated.
RS-274X (Extended Gerber): Embeds aperture definitions and layer attributes
inside the file; became the de facto standard for fabrication.
Gerber X2: Adds metadata (layer functions, net names, component/pad attributes)
to improve CAM automation and reduce human error.
Today: Most fabricators accept RS-274X and X2. Provide Excellon drill files alongside
Gerbers.
Common Mistakes to Avoid
Missing or mismatched drill files (no .DRL, wrong units, or inconsistent origins).
Incorrect layer polarity or exporting negative/positive incorrectly for solder mask
and paste.
Unintended copper slivers and acute angles due to insufficient trace/clearance rules.
Tiny text and line widths in silkscreen that the printer cannot resolve.
Forgetting board outline or providing multiple conflicting outlines.
Inconsistent units/origins across Gerber and drill files (e.g., mm vs. inch; absolute
vs. incremental).
Verification Checklist (Pre-CAM Review)
Open the full set in a Gerber viewer (e.g., KiCad GerbView, gerbv) and visually
verify:
– Layer-to-layer alignment (copper, mask, silkscreen).
– All holes present and correctly sized; plated vs. non-plated distinguished if needed.
– Mask openings properly expose pads and do not create solder bridges.
– Silkscreen does not overlap pads or vias; minimum text height/line width re-
spected.
– Board outline is single, continuous, and unambiguous; tooling slots/milling
shown where required.
Cross-check units, format (e.g., 4:4, 3:5), and origin between Gerber and drill.
If using Gerber X2, confirm layer functions (e.g., Top Copper) are correctly tagged.
Drill Files and Coordinates
Format: Excellon (.DRL); include tool table (diameters) or a separate .TXT drill report.
Units: Stick to metric (mm) for modern workflows. If using inch, ensure all files use
the same units.
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Coordinate Mode: Prefer absolute over incremental. State zero suppression (lead-
ing/trailing) if applicable.
Plated vs. Non-Plated: Use separate drill layers or attributes for NPTH vs. PTH
to avoid fabrication ambiguity.
Recommended CAM Export Settings
Setting Recommendation
Gerber standard RS-274X or Gerber X2 (preferred)
Format / Resolution 4:6 or 4:5 (sufficient precision for most boards)
Units Millimeters (mm)
Zero suppression Leading (consistent across all layers)
Polarity Positive for copper/silkscreen; verify mask layers
Drill output Excellon with tool table; absolute coordinates; mm
Solder mask swell According to fab notes (e.g., +0.05 mm typical)
Silkscreen min text Height ≥ 1.2 mm; line width ≥ 0.15 mm
Clearances Per DRC/IPC class; confirm against fabricator capabil-
ities
Submission Package Checklist
All Gerber layers (.GTL, .GBL, .GTS, .GBS, .GTO, .GBO, .GKO/GML, ...)
Drill file(s) .DRL + drill map/report.
Readme/fab notes: stack-up, copper weight, finish (ENIG/HASL), mask color, silkscreen
color.
Panelization and tooling notes if applicable (rails, fiducials, mouse-bites, V-grooves).
Compress into a single .zip before upload.