Introduction to PCB-to-Gerber Conversion

Printed Circuit Board (PCB) design is a crucial step in the electronics manufacturing process. Once the PCB design is complete, it needs to be converted into a format that can be understood by the manufacturing equipment. This is where Gerber files come into play. Gerber files are the industry standard for PCB fabrication, and they contain all the necessary information required to manufacture a PCB.

In this article, we will focus on how to export a PCB designed in DipTrace to Gerber files. DipTrace is a popular PCB design software that offers a user-friendly interface and powerful features for designing PCBs.

What are Gerber Files?

Gerber files are a set of files that contain all the information needed to fabricate a PCB. They are named after the Gerber Systems Corp., which developed the format in the 1960s. Gerber files are essentially a set of instructions that tell the manufacturing equipment how to create the PCB.

Gerber files include information such as:

• Copper layers
• Solder mask layers
• Silkscreen layers
• Drill files
• Outline files

Each layer of the PCB is represented by a separate Gerber file. For example, a two-layer PCB would have two copper layer files, one for the top layer and one for the bottom layer.

Why Use Gerber Files?

Gerber files are the industry standard for PCB fabrication for several reasons:

1. Universality: Gerber files can be read by any PCB fabrication equipment, regardless of the manufacturer or the software used to create the files.

2. Accuracy: Gerber files provide a high level of accuracy and precision, ensuring that the manufactured PCB matches the original design.

3. Simplicity: Gerber files are simple and easy to generate, making the PCB-to-Gerber conversion process straightforward.

4. Reliability: Gerber files have been used for decades and have proven to be a reliable format for PCB fabrication.

Exporting PCB to Gerber Files in DipTrace

Now that we understand what Gerber files are and why they are important, let’s dive into the process of exporting a PCB designed in DipTrace to Gerber files.

Step 1: Verify the PCB Design

Before exporting the PCB to Gerber files, it’s essential to verify that the design is complete and error-free. Here are some things to check:

• Ensure that all components are placed correctly and oriented properly.
• Check for any overlapping or missing traces.
• Verify that the PCB dimensions are correct.
• Ensure that all the necessary layers are included in the design.

Step 2: Set Up the Gerber Export Settings

Once the PCB design is verified, it’s time to set up the Gerber export settings in DipTrace. Follow these steps:

1. Go to “File” > “Export” > “Gerber…”
2. In the Gerber Export window, select the “General” tab.
3. Choose the appropriate units (inches or millimeters) for your design.
4. Select the desired format for the Gerber files (RS-274X or RS-274D).
5. Choose the coordinate format (absolute or incremental).
6. Set the resolution (typically 6 or 8 digits after the decimal point).

Here’s a table summarizing the common Gerber export settings:

Setting	Options
Units	Inches, Millimeters
Format	RS-274X, RS-274D
Coordinate Format	Absolute, Incremental
Resolution	6 digits, 8 digits

Step 3: Select the Layers to Export

Next, select the layers that you want to export to Gerber files. DipTrace allows you to export individual layers or all layers at once. To select the layers:

1. In the Gerber Export window, go to the “Layers” tab.
2. Check the boxes next to the layers you want to export.
3. Assign a file name and extension to each layer.

Here’s an example of how you might name the Gerber files for a two-layer PCB:

Layer	File Name	Extension
Top Copper	PCB_Top_Copper	.GTL
Bottom Copper	PCB_Bottom_Copper	.GBL
Top Solder Mask	PCB_Top_Solder_Mask	.GTS
Bottom Solder Mask	PCB_Bottom_Solder_Mask	.GBS
Top Silkscreen	PCB_Top_Silkscreen	.GTO
Bottom Silkscreen	PCB_Bottom_Silkscreen	.GBO
Drill Files	PCB_Drills	.TXT
Outline	PCB_Outline	.GKO

Step 4: Export the Gerber Files

Once you have set up the export settings and selected the layers to export, you’re ready to generate the Gerber files. Click the “Export” button in the Gerber Export window, and choose a location to save the files.

DipTrace will generate a separate Gerber file for each layer you selected, as well as a drill file and an outline file. These files will be saved in the location you specified with the file names and extensions you assigned.

Step 5: Verify the Gerber Files

After exporting the Gerber files, it’s a good idea to verify that they are correct and complete. You can use a Gerber viewer software to open and inspect the files. Some popular Gerber viewer software include:

• GerbView (free)
• ViewMate (free)
• CAM350 (paid)

When verifying the Gerber files, look for any errors or discrepancies, such as missing layers or incorrect dimensions. If you find any issues, go back to your PCB design in DipTrace and make the necessary corrections, then re-export the Gerber files.

Best Practices for PCB-to-Gerber Conversion

To ensure a smooth and error-free PCB-to-Gerber conversion process, follow these best practices:

1. Keep the PCB design simple: Avoid unnecessary complexity in your PCB design, as it can lead to errors and difficulties in manufacturing.

2. Use a consistent naming convention: Establish a clear and consistent naming convention for your Gerber files to avoid confusion and errors.

3. Communicate with your PCB manufacturer: Consult with your PCB manufacturer to ensure that you are providing all the necessary files and information they need to fabricate your PCB.

4. Double-check your work: Always verify your PCB design and Gerber files before sending them to the manufacturer. Catching errors early can save time and money in the long run.

Frequently Asked Questions (FAQ)

1. What is the difference between RS-274X and RS-274D Gerber formats?
   RS-274X is the more modern and widely used Gerber format. It includes feature and aperture information within the Gerber file itself. RS-274D is an older format that requires a separate aperture list file.

2. Do I need to export all layers to Gerber files?
   It depends on your PCB design and manufacturing requirements. At a minimum, you’ll need to export the copper layers, solder mask layers, and drill files. Consult with your PCB manufacturer to determine which layers they require.

3. Can I use different units for different layers in Gerber files?
   No, all layers in a set of Gerber files must use the same units (either inches or millimeters). Mixing units can lead to errors in manufacturing.

4. What resolution should I use for Gerber files?
   The standard resolution for Gerber files is 6 or 8 digits after the decimal point. Higher resolutions can provide greater accuracy but may also result in larger file sizes.

5. How do I know if my Gerber files are correct?
   Use a Gerber viewer software to open and inspect your Gerber files. Look for any missing layers, incorrect dimensions, or other errors. You can also send your Gerber files to your PCB manufacturer for verification before placing your order.

Conclusion

Exporting a PCB designed in DipTrace to Gerber files is a critical step in the PCB manufacturing process. By following the steps outlined in this article and adhering to best practices, you can ensure that your Gerber files are accurate, complete, and ready for fabrication.

Remember to always verify your PCB design and Gerber files before sending them to the manufacturer, and don’t hesitate to communicate with your manufacturer if you have any questions or concerns.

With a solid understanding of the PCB-to-Gerber conversion process and the tools available in DipTrace, you’ll be well on your way to creating high-quality PCBs that meet your design and manufacturing requirements.