There are modern software solutions that can help to do that level of checking and bring the creation of useless printed circuit boards to an end. They guarantee your work is heading into production without errors, and they are often called Gerber file viewers.

Should You Run Printed Circuit Board Designs Through a Gerber File Viewer?

Standard PCB design uses Gerber files. Most involved in the industry know all about a Gerber file and how to read one. It enables standardization in design and eliminates glitches caused by any attempts at merging different kinds of files.

Are PCBs so complex? Printed circuit boards are found in and also contain electronic components. They may feature resistors and capacitors and run complex or simple operations. Circuits are mounted to the board, and the various elements within a board communicate through conducting materials like copper lines.

Gerber files detail these connections and components and will show the many layers that printed circuit boards may require to do their job. Gerber files, however, may also be used by PCB printing devices to make the boards. They may guide the production of a PCB directly from the design, depending upon the information within the files.

To date, there have been three generations of Gerber files:

• Standard Gerber, RS-274-D was the first generation
• Extended Gerber, RS0274X was the second generation
• Gerber X2 is the latest generation and also often includes metadata

A single Gerber file corresponds or details a single layer on printed circuit boards, one file for each layer, including inner layers, as well as top or bottom signal layers. Historically, manufacturers would work directly with designers and go over the Gerber files to ensure no issues. Today, things have changed, and a manufacturer may whip up a batch of printed circuit boards without evaluating or scrutinizing the Gerber files.

As many recognize, this can lead to a lot of trouble. Flawed layering, failed communications, and other issues may leave an entire batch of PCBs useless to the buyer. Fortunately, the use of a Gerber file viewer may save the day.

Using the Gerber File Viewer

Gerber file viewers were designed and created to address the issue of flawed PCB design. Today, there are many types of Gerber file viewers on the market that allow PCB designers to see how the various layers will operate as a physical PCB.

While there are many programs, Advanced Circuits makes an entirely free tool of this kind available to its customers. It requires a quick upload of Gerber files into the system and is free whether or not the user is a registered customer of the company.

Known as FreeDFM, it does a comprehensive evaluation of the design. It looks at all of the inner layers and evaluates such issues as spacing, trace width, annular ring, inner clearance, and thermal reduction. It also analyzes the outer layers’ similar areas, checking spacing, trace width, and annular ring. It looks at physical production issues like drilling and evaluates solder mask for undersized or missing clearances. It checks the silkscreen for line width.

After this comprehensive review, it generates an easy-to-understand report in a PDF format. It provides its full findings of the Gerber file review, and while it may make some basic repairs, it also identifies issues that a designer must address. For example, one of the more common design flaws is missing or incomplete data. FreeDFM will ensure that files have the required data.

One of the most significant benefits of the Gerber file viewer is its ability to correct common design issues automatically. It fixes small issues on-the-fly, cutting down on designer’s workloads and delays. The information taken from the evaluation also helps to generate an accurate quote for PCB production.

Additional Benefits

The free Gerber file viewer is an ideal tool for error-free production. Yet Advanced Circuits also offers an array of other services and resources, including:

• Fast service – Speedy turnaround time and fast shipping ensures that customers get their PCBs quickly.
• Custom orders – Custom orders are welcome for PCB prototypes or full batches.
• No tooling charges – When an order features Standard Specifications, tooling charges are waived and similar fees are canceled on reorders of Standard Spec as Custom Spec items.
• No minimum orders – There are no minimum lot requirements, meaning that clients are not forced to invest in huge orders with more PCBs than they might need or used.
• Not a broker – The company never subs out their work, but instead, relies on their top-of-the-line, 62,000-square-foot facility that guarantees the kind of quality and speed most customers want but don’t always get.
• 24-hour support – Customer service around-the-clock is great, but they also feature a live tech support team that allows design teams to speak directly with a CAM engineer at any hour of the day or night.
• Best shipping record – Advance Circuits has the best on-time shipping record in the industry, and they are now shipping 50% of orders early! In fact, they say they “put our money where our mouth is . . . and we ship Standard Spec orders on time, or they’re FREE!”

Whether it is a new company seeking a maker of printed circuit boards or a long-standing firm eager to up the quality and experience with a PCB manufacturer, Advanced Circuits has the resources needed. With free evaluations through the Gerber file viewer, designs will be better than ever, and PCBs can be as innovative or as simple as needed and always reliable.

Writing them without errors, though, is easier than it may seem. Gerber files are digital blueprints for your PCB. They detail each layer and shape the fabrication process that will be used to make even the most innovative designs. Many producers demand Gerber files, even if they are an assembly-only part of the process. This is to ensure clarity on all of the physical attributes of a PCB.

This means that even a single mistake will lead to all kinds of delays, financial issues, production problems, and losses. If you are using a “no-touch” manufacturer or fabricator, it also means it is a “no review” production process. They don’t analyze your Gerber files or PCB design, and it makes it easier than ever for incomplete, flawed, or inaccurate Gerber files to make their way into production, resulting in a PCB that doesn’t work.

Is the Gerber file so wrought with potential disaster as to make it a problem? No, it is simply that there are common glitches that are easily overlooked.

Common Glitches to Consider When Working with Gerber Files

Many are unaware of the most common problems with Gerber files, but it is immensely useful to know about them when entering into the PCB design and production process. These problems include:

• Empty files – Any designer may unintentionally delete or negate file content, leaving a 0-byte file that offers no workable data for the production or fabrication team.
• Flawed file naming protocols – Among the most common concerns with Gerber files is the use of a flawed file naming protocol. Leading to confusion for others involved in the process, this also complicates file checking or troubleshooting.
• Incomplete or missing data – Empty files are one thing, but it is also possible for details or information to be lacking or mismatched against the specifications delivered to a manufacturer. It is crucial for Gerber files to be where they belong, accessible, and complete.
• Conflict between layers – Some software creates multiple Gerber files with design specs at every layer. Should those layers fail to be combined synchronously, it can lead to composite layer design errors outside of individual layer design specs.
• Aperture lists – When Gerber files are in use, it is best to have a single aperture list with details the fabricator or manufacturer will need, as well as specs relating to the tools necessary for each stage. Multiple lists can mean errors, and the format of the lists should be in sync with the Gerber file format, as well.

Those experienced in Gerber file creation may think of such mistakes as avoidable or inexcusable, but they are common events. They doom most projects to huge production costs, lengthy delays, and failure. Avoiding them requires attention to detail, the use of high-definition CAD programs, implementing the best quality assurance practices from start to finish, and using a Gerber file viewer.

Because problems are so common, the best PCB manufacturers and fabricators offer free resources to prevent such issues.

Advanced Circuits Offers Support for Flawless Gerber Files

Advanced Circuits is among the top names in the PCB and prototype assembly industries. With the ability to handle PCB manufacturing (fabrication) and assembly, it provides clients with services that help improve all projects, especially the quality of their Gerber files. This is done by making a range of free resources available that support the creation of projects from first phase to final product.

Advanced Circuits offers the following options:

• The Advanced Circuits website has free PCB file check software for those with complete Gerber files ready to enter production. Known as FreeDFM, it is a program that will rapidly evaluate printed circuit board design files, correct many issues, and send a full report that identifies any other issues that could present problems along the way. Those who use this tool get a discount for simply running the files through the program. It does require an import of Gerber files (via an online upload). However, the software is free to use, and it will utilize the registered email address to send all of the analysis (in a PDF report) as well as the discount code.
• PCB Artist As anyone familiar with PCB design and manufacturing knows, most customers rarely get to tour a fabricator’s facilities or work one-on-one to address issues or avoid common errors. Once a great way to prevent problems, the global nature of PCB production makes this impossible. This is why Advanced Circuits offers another resource – the free PCB Artist program. This has a long list of features that guarantee an error-free design process and includes unrestricted design capabilities with a 28-layer limit, a controlled auto-router function, multi-page schematics, and more. This is not the same as Gerber files but includes a full library of tutorials that help all users to create flawless files.
• Free Gerber file reviews, corrections, and reporting by an engineering expert.

Further Resources to Trust

While this array of design resources proves invaluable to many, Advanced Circuits also dedicates itself to client satisfaction and success in other ways. For example, work is never subcontracted, there are never tooling fees if an order sticks to standard specs, and there is 24-hour tech support provided by a CAM engineer. They make no minimum order requirements and have the best on-time shipping record in the industry, with many orders arriving ahead of schedule. They are so sure they can meet customer needs that Standard Spec orders are FREE if they fail to arrive on time.

Gerber files can be a major hassle, but the tools and services available via Advanced Circuits support only the best results. Avoiding costly errors and long production delays are a thing of the past when your files are created without errors or problems.

There are many tools and resources used in the PCB layout, design, and manufacturing processes, and this leaves a lot of room for error and waste. One small glitch and production delays may occur, or entire batches of PCBs end up tossed into the trash. Thus, it is best to start with the best design and layout, and this is where software and experts can save the day.

Advanced Circuits offers an astonishing range of PCB layout and design tools that can almost guarantee a simple and flawless process. It all starts with the right file types…

Gerber Files and PCB Layout

IX274X files (typically called Gerber files) are the most commonly used for PCB layout and design. They are what we might call the first step in production and are often described as digital or physical blueprints for the printed circuit boards to be manufactured.

Typically, designers or engineers would print layers of transparent films or overlays that were color-coded to show the PCB layout and to support design evaluations. In other words, the layers could be looked at individually or all at once to detect glitches or shortcomings.

The creation of PCB layout software and programs gave designers and manufacturers the ability to eliminate the printed films and to begin to adjust the layers with greater ease. Though they might still be described as blueprints, Gerber files may still have design or function flaws.

Even if an expert uses the best PCB layout tools, there could be problems in the file, and it could cause a production delay or result in a batch of useless PCBs. This is particularly true if the PCBs are being made by a no-touch resource or outsourced producer. For instance, the overall appearance of a Gerber file or PCB layout may look acceptable to the untrained eye. A subcontracted producer may not even review the files but simply use them to make the entire batch of PCBs without any troubleshooting or evaluation. This can easily result in a long list of problems if there is a flaw in the design, including scheduling, production, and financial issues.

Use Optimal PCB Layout and Design Tools

This is why it is so valuable to find producers of PCBs able to offer services and resources that avoid such issues. For example, a tool that can evaluate a Gerber file and detect or even correct errors can be a lifesaver. At Advanced Circuits, clients can count on tools meant to ensure that PCB layout and design are exactly as needed, even correcting some errors, generating reports, and offering discounts along the way.

Here are a few of the tools Advanced Circuits offers to clients.

Free PCB Design Software and Analytics: As one of the most trusted domestic producers of PCBs and prototypes, Advanced Circuits provides full design to shipping services. There are also full assembly services that can all be put to use to ensure clients avoid costly errors. Using free design and evaluative tools, customers (whether using Gerber files or another design program) can export design files into the company’s free PCB file check software known as FreeDFM. They then receive a comprehensive analysis of the layout and design.

Then, the free software quickly evaluates and repairs problematic issues in the PCB layout and design files and generates a report of any questionable issues left uncorrected. Labeling them as problems, it ensures that a customer cannot waste time or resources on flawed or unusable batches of PCBs. And even more exciting is that those who run the Gerber files before submission enjoy a discount on the project.

PCB Artist: This unrestricted version of the leading PCB layout and design software is provided to all clients. It can be used to design PCBs of up to 28 layers and features a library of more than 500k common parts and components. This is in addition to the troubleshooting software and comes with such functions as controlled auto-routing design tools, digital schematics, and much more. It helps reduce risks of a flawed layout or design, and the files from this are also capable of the same evaluation and analysis.

Common PCB Layout and Design Issues

 What types of problems will the software evaluate and/or correct? The most common include:

Empty files: Designers frequently move, erase, or negate data, and this inserts zero data files into the process, which runs the risk of causing issues in the design and fabrication process.

Missing data: While an empty file is bad enough, a file with incomplete data is worse. Using free PCB layout software and checking services indicates when data cannot align with job specifications or when information is mismatched. Gerber files must not be without key data, so any opportunity to eliminate problems of this kind will save a lot of time, money, and headaches

Flawed file name: It is not at all unusual for Gerber files to be created via a flawed naming protocol. This causes confusion within the process and can only be detected by file checking or troubleshooting ahead of the game.

Conflicting layers: Gerber files feature design specifications at every layer. The designer must ensure that the specs function synchronously, or there will be errors at every subsequent layer.

There is no real reason for any glitches to occur in the layout and design processes, but there are many reasons for such mistakes to occur at other times. Accessing free resources like those from Advanced Circuits erases almost all risks and helps customers to ensure that their layout, design, fabrication, and manufacturing processes are moving smoothly and result in the PCBs needed for production.

However, if you do not make use of a quality Gerber file viewer, you may find some issues. Even after you have spent a long time making sure that the board has been designed perfectly, it is still possible for errors to exist in the Gerber files. It is very frustrating to have this happen.

Fortunately, there are things you can do to find and handle these problems before they take control. In addition to having a quality design from the start, using a Gerber file viewer to locate issues is very important. Even if you are creating a relatively simple circuit board, you will find that having a file viewer can help to cut down on errors. Even the best designers and engineers can make mistakes. Viewing the Gerber files can help to ensure those mistakes do not persist and cause further problems.

What Are Gerber Files?

Before delving into how a file viewer can help, it is a good idea to have an understanding of what Gerber files are and why they are important. The files are considered the industry standard for printed circuit boards, which means they are what everyone knows and uses.

It has become the industry standard because Gerber is robust and able to describe a range of different circumstances regarding the board that everyone who is familiar with the file system can understand. It also makes it easier to send files out to a manufacturer because everyone is working from the same base. The Gerber file format should be used to ensure there are guidelines for the manufacturer. It describes the components of the PCB image, communicating the information to the manufacturer in a way they will understand.

Over the years, there have been several generations of Gerber files. These include the first generation, RS-274-D, which is also often called Standard Gerber. Extended Gerber, RS0274X is the second generation. The most recent Gerber file format is called Gerber X2.

Easily Check Your Gerber Files

Creating high-quality designs does not always mean you haven’t made any errors. There could still be issues that a Gerber file viewer can help to find so you can fix them. At Advanced Circuits, we offer a PCB file viewer, which makes it easy for you to add your files and view them. You can quickly and easily find out if there are any problems with the files before you move forward. One of the best features of our file viewer is that it can correct some types of problems automatically. This helps to speed up the process even further.

Our free file viewer software is very simple to use. Once you have exported files from the software program you are using to design the PCB, all you need to do is load them onto our site’s file viewer. It is a free system, and you can get your results very quickly. Just add your email address, so the results of the check can be sent to your email.

If there are issues with the design, you will be alerted in the results that are emailed to you. The report that you receive is graphical and very easy to understand. If there are remaining problems, you will know exactly what you need to address. As mentioned, it is sometimes possible for the software to fix certain issues automatically. In the results, you will find out if any issues were automatically corrected.

One of the other benefits of using Advanced Circuits is that we also provide free PCB Artist software. This is an ideal solution for those who need a quality, reliable program to create their printed circuit boards from the ground up.

If there are issues that were not corrected automatically, you will at least know where they are located. This allows you to go back to the proverbial drawing board, so you can then fix the issue or issues on your own.

Being able to check the files helps to eliminate the risk of trying to send through files for production that have errors in them. For anyone who is working in the field and even those who might be making a few prototypes for personal projects, errors cause delays. When projects are delayed, they can cost money, not to mention a substantial amount of frustration. Using a high-quality Gerber file viewer helps to cut down on these issues substantially.

How Else Will Advanced Circuits Help You?

As mentioned, Advanced Circuits also provides PCB Artist software, which makes it faster and easier to create a high-quality PCB design. It is powerful and easy-to-use software that is entirely free for those who want to use it. There are other benefits to working with us that you will discover.

We can provide a speedy turnaround time for those who are looking to have their PCBs manufactured. Not only are we able to manufacture quickly, but you will find that we are also able to ship quickly. We have been in the field for years and have become not only one of the largest companies in the industry but also one of the most trusted. There are no minimum orders when working with us, either. Whether you need one or two boards or you need 10,000, we can provide you with the help you need throughout the project.

Regardless of where you are in your design for a printed circuit board, it is time to check out all that Advanced Circuits can offer. From design software to a Gerber file viewing, manufacturing, and more, we have what you need. Get in touch and make sure that your board is error-free and ready for printing.

Find the Problems Early

If there are errors in these files – even just a single error – it can cause problems with your production schedule. If you are using a no-touch manufacturer that doesn’t even look at what they are creating, it could cause you to have thousands of useless PCBs delivered to you. You have to know whether your PCB is ready to take to production or not.

If there are errors, you have to take time to find out what is wrong, and you need to fix it. This would be a time-consuming process if it weren’t for the availability of a Gerber file viewer. This can help you find both common and uncommon Gerber file errors, so you don’t end up sending a bad design to be manufactured.

Types of Gerber File Errors

There are many types of Gerber file errors that could cause issues with your PCB. One of the most common is missing drill files. These files are used to determine the location and the size of the holes that need to be drilled. Since many PCBs require that holes are drilled into them, this is important information that will need to be there for the manufacturer.

Sometimes, the files might have missing outlines, or they might have double outlines. There could be issues with a mismatched PCB size, the drill hole placement might cut into the tracing, or the plated and non-plated holes might not be defined clearly. The layer labeling might not be clear, and having naming protocols that are not effective can lead to confusion. It can also cause problems for you when you are trying to check the files and do the troubleshooting for the circuit. It is important that you make sure the labeling system is clear and understandable.

Something else that you will want to keep in mind is that you should have just a single aperture list. There might be a temptation to have different lists, but this can cause confusion with the manufacturer. They might not see the list, or you might have inadvertently put conflicting information on two different lists. Having just a single aperture list is always a good idea.

Common Errors Easily Caught

Even though these mistakes might seem simple, they happen relatively frequently. When they occur, it means that it will take time, energy, and money to find the mistakes and correct the errors. If the PCBs were to go into production at this point, it could mean a massive waste of money on your part. You do not want to go through any of these issues, and you certainly don’t want to make mistakes with your Gerber files.

Fortunately, there are some things you can do to help relieve these types of issues and catch problems early. This will ensure that you can fix those problems before they affect the actual production.

How a Gerber File Viewer Can Help

One of the best things to do is to use a Gerber file viewer, which will allow you to more quickly and easily find problems with your files. There are Gerber file viewers online that you can use, and one of the best is offered through Advanced Circuits. With our PCB file viewer, FreeDFM, you will be able to add your files to the system and find the potential problems that exist. Unlike some of the other Gerber file viewers, you will find that this software even has the ability to correct certain issues automatically.

The software is easy to use. You will have to export files from the program you are using and then load them online to the site. Best of all, the software from Advanced Circuits is free to use. All you need to do is supply an email address where the results will be sent after the file is checked. You will receive a report that will let you know about any issues that were found with the PCB design, and it can provide details about those problems. It will also let you know what problems were fixed by the software.

If you have been designing your circuits using these files, as many do, it is imperative that you use a Gerber file viewer. It can help you to eliminate headaches down the road that would cause production delays and increased costs.

Other Ways Advanced Circuits Can Help

In addition to the free Gerber file viewer, Advanced Circuits offers free software called PCB Artist. This software provides users with a range of features and benefits, including more than half a million parts and the ability to design PCBs that are up to 28 layers. The software can be downloaded right through the site. It can make the process of designing and getting the circuits ready to prototype and manufacture faster. While the system is easy to use, there are also video tutorials, a user’s guide, and tips and tools on the site that can help you to get started. Through the use of the software, you’ll reduce the risk of errors in your PCB designs.

In addition, Advanced Circuits provides high-quality customer service for clients. There is 24-hour tech support, so you can always get in touch with a CAM engineer if needed. You will be able to order only as many circuit boards as you need, since we don’t require a minimum order. We can provide you with fast turnaround times, fast shipping, and customer service that helps to ensure that you are getting the boards that you need. Get in touch with Advanced Circuits for a quote, and learn more about how we can help with your manufacturing needs.

These viewers can help to eliminate issues with the manufacturing of the board, as you can get the data and feedback you need. This will ensure that you are not sending out work that is incorrect to the manufacturer. Everyone who is designing a circuit board, regardless of how simple or complicated it might be, will benefit from a Gerber file viewer.

What Are They and How Do They Work?

To understand the benefits of a Gerber file viewer, it is important to understand more about printed circuit boards. PCBs are boards that contain electronic components. These might include capacitors and resistors, for example. The circuits are mounted to the board, and elements of the board are connected through thin strips of conducting material. This is often copper.

The Gerber file format is considered standard in PCB design. This means that most people in the field will know and understand what a Gerber file is and how to read it. It helps to have a standard that can be used throughout the industry rather than having multiple proprietary files.

The Gerber file describes and communicates the components of the PCB image, such as copper layers and other attributes. Gerber files can also be input files for PCB printing devices that can make or compare circuit board images. They are essentially “sketches” that provide information about the makeup of the circuit boards. They help to guide the production of the PCB from the design. There have been three generations of Gerber files.

The Standard Gerber, RS-274-D, was the first generation. Extended Gerber, RS0274X, was the second generation, and Gerber X2 is the latest generation.  Modern Gerber files will also often include metadata.

Each of the Gerber files will equal, or correspond to, a single layer in the physical board. This could be the bottom signal layer, the top signal layer, inner layers, etc. In the past, it would often be necessary to provide the manufacturer with the Gerber files, which they would use to manufacture the PCB. This meant that it was not always possible to catch issues in the design until it was too late.

The Introduction of the Gerber File Viewer

To make the process faster and easier, the Gerber file viewer was created. This is a software that will allow you to check the contents in a Gerber file. It is a fast and easy way to get a better understanding of the design and how it will translate to the actual PCB. There are many tools on the market, including software that can be downloaded and installed on a computer.

However, we’ve opted to make the process even easier for our clients. We at Advanced Circuits provide a free to use tool that is right on our website. You can upload your Gerber files for viewing on your own time. The tool is available around the clock, and it works easily. Anyone who has a Gerber file can use the tool to upload and view. They do not have to be an active customer to use the software.

Our Gerber file viewer, called FreeDFM, can look at the inner plane layers for spacing, trace width, annular ring, inner clearance, and thermal reduction. It can check the outer layers for spacing, trace width, and annular ring. It can check drilling for double hits and missing hits. It also checks the solder mask for undersized clearances and missing clearances. It checks the silkscreen for line width. The inner signal layers can be checked for spacing, trace width, annular ring, and inner clearance.

Our system will provide you with an easy to read graphical report. This can make it much easier to understand the findings from the Gerber file viewer, so you can easily see if there are problems you will need to address. We can ensure that the files contain all the needed data, and one of the most significant benefits of our viewer is that it can automatically correct some design issues. This means that if you have some small issues, they could be fixed for you automatically, which can help to reduce your workload.

Besides the information that can be gleaned from the Gerber file viewer, we can also provide you with a detailed PCB quote.

We make the system as easy to use as possible. You will first want to export your Gerber files from the design software and then upload a zip folder to the online tool. You can then provide your email address, where the results will be sent in a matter of minutes.

Why Choose Advanced Circuits?

In addition to our free Gerber file viewer, we can provide you with a wealth of other benefits when you work with us. We’re known for our speedy turnaround time and rapid shipping, which ensures that you get your PCBs quickly. We are one of the largest companies in this field, and we can provide you with reliable service, manufacturing, and assembly. If you have custom orders in mind, we can help with those. Also, there are no minimum order requirements for PCB orders.

Those who need a company that can reliably manufacture their PCBs will want to check out everything that Advanced Circuits has to offer. We can provide you with the services you need and using the Gerber file viewer helps to ensure that you are getting a great board that works the way it should.

Gerber Files and PCB Design Software

Gerber or IX274X files (they are the same) are the end products from the most commonly used PCB design software options. They are what can be called “step one” in the production or manufacturing process; they are the digital or physical blueprints for the completed printed circuit board. In the past, experts generated layers of transparent film overlays that used color coding to delineate the different areas of the board, and offer some help with identifying design flaws.

The advent of advanced PCB design software, however, has allowed manufacturers or design teams to cut down on the steps and use the software to display and adjust the layers. The initial designs generated from the PCB design software focus on the design and maybe the process used for assembly. They do not highlight any areas of concern or error.

This means that even a blueprint generated by the finest PCB design software, and used by a skilled expert, may contain errors in the Gerber (or other file types) that lead to a batch of useless boards. This is especially true in our modern age of outsourcing and production-only services.

Consider that one undetected problem in the Gerber file for a printed circuit board may pass unnoticed through the hands of the subcontractor. They are likely to be overseas or what is deemed a “no touch” producer that just uses the files and makes the boards, and this means that an entire batch of PCBs can be made, and create a financial, production, or scheduling nightmare.

That is why it is imperative for any companies using printed circuit boards to identify the best PCB design software and resources intended to avoid those issues. It is also important for any team to understand where flaws in Gerber files might prove their downfall, and how to overcome such risks. While it is putting the cart before the horse to offer the solutions before itemizing the problems, it is helpful to understand that there are options for PCB design software and evaluation tools that can eliminate all the risks present.

Free PCB Design Software and Analytics

Advanced Circuits rates as one of the most trusted and popular domestic producers of PCBs and prototypes. Offering full design to shipping services, and assembly, we also help our clients  avoid the costly errors just itemized above through the use of free design tools. Whether using Gerber files or another design program, the Advanced Circuit site has an option for exporting design files into the site’s free PCB file check software, known as FreeDFM, and getting a comprehensive analysis on the design. By uploading the files, entering contact information, and sending it into the analysis engine, a client gets a full analysis of the design. The software quickly evaluates and repairs problematic issues in the printed circuit board design files, and also generates a report of any questionable issues left uncorrected. Labeling them as potential showstoppers, it ensures that a customer does not waste time or money on flawed or entirely useless production jobs. And even more exciting is that those who run the Gerber files before submission enjoy a discount from Advanced Circuits on the project.

In addition to the troubleshooting software, Advanced Circuits also makes industry-best design software available entirely free for clients to use. The free PCB Layout Software known as PCB Artist is provided in an unrestricted format (along with a library of more than 500k common parts and components) and can be used to design PCBs of up to 28 layers. With such functions as controlled auto routing design tools, digital schematics, and much more, it also cuts down on the risks of a flawed design. Files generated through this program can also be run through the file check to ensure the best outcomes and a discount on the work.

And just what sorts of problems will these tools help erase from Gerber files? The most common include:

• Flawed file names– It is not at all unusual for Gerber files to be created via a flawed naming protocol. This causes confusion within the process, and can only be detected by file checking or troubleshooting ahead of the game.
• Empty files – In addition to flawed names are empty files. Designers frequently move, erase, or negate data and this inserts zero data files into the process, and which runs the risk of causing issues in the design and fabrication process.
• Missing data – While an empty file is one thing, a file with incomplete data is another. Our free PCB design software and checking services show when details don’t line up with specifications or when there is mismatched information. Gerber files must not be void of key data, so any opportunity to eliminate such a glitch will save a lot of time, money and headaches.
• Conflicting layers – Gerber files feature design specifications at every layer. The designer has to ensure that the specs function synchronously, or there will be errors at every subsequent layer.

Correctly Designed & Manufactured Printed Circuit Boards

There is no real reason for any glitches to occur in the design process, but there are many reasons that they can and do. Using free resources like those from Advanced Circuits cuts down on any potential risks plus helps a company keep design, fabrication and manufacturing moving smoothly.

Upload PCB design files to FreeDFM here.

You can innovate and use your design resources to make that happen, and it is likely that at the bottom of it all, though, are those Gerber files. They are the digital blueprints of the PCB and explain every layer and outline the fabrication process to follow. This is why some firms want the Gerber files even when they are handling assembly-only processes – to understand all physical attributes of the PCBs.

A single error in the Gerber files, can lead to a financial, scheduling, and production disaster. This is particularly true in the current era when “no-touch” and even “no review” processes are put to use by manufacturers or fabricators. Your job becomes designing the PCB to your needs, running tests, and hoping that there are not inaccurate, incomplete or otherwise flawed files sent to the manufacturer.

Common Issues with Gerber Files

As odd as it might seem at this point in time, there are some common issues with Gerber files, and it can help to be aware of them wherever you stand in terms of PCB design expertise:

• Empty files – There are many instances when a designer may inadvertently delete or somehow negate file contents, leaving a 0-byte file that provides no useful data to the production or fabrication team.
• Flawed file naming protocols – One of the more common glitches when Gerber files are put to use is that the design team fails to use an effective naming protocol, leading to confusion for others involved in the process, and complicating file checking or troubleshooting.
• Incomplete or missing data – Empty files are one thing, but there are also instances when details or information may be lacking or mismatched against the specifications delivered to a manufacturer. Though it can be a very time-consuming process, it is essential that Gerber files are accessible and where they belong.
• Conflict between layers – Often, software generates multiple Gerber files with layer design specs at each layer. If the layers are not combined in a synchronous way, it can lead to composite layer design errors outside of individual layer design specs.
• Aperture lists – A single aperture list is ideal when Gerber files are in use. It should have any details the fabricator or manufacturer will need and details about tools necessary for each stage. With more than a single list, confusion can ensue and errors increase. The format of the lists should be in sync with the Gerber file format, too.

And while such mistakes are often deemed inexcusable, they occur frequently enough to doom many projects to destructive costs, lengthy production delays, and more. To avoid them means attention to detail, using high definition CAD programs, adhering closely to the best quality assurance practices from start to finish, and putting a Gerber file viewer to use.

Of course, issues created by even a single problem with the files has led to some of the best PCB manufacturers and fabricators providing resources to work around the issues. There are a host of troubleshooting or even trouble-avoidance solutions, but not all companies offer them to clients, and few do so for free.

Let Advanced Circuits Help You Avoid Problems with Gerber Files

At Advanced Circuits, we rank as one of the top companies in the PCB and prototype assembly industries. Able to tackle both PCB manufacturing (fabrication) and assembly, we also offer clients exclusive services that support, facilitate and improve any project while cutting down on risks for problems with Gerber files.

How? We make an array of free resources available through our site, and we can serve as a start to finish solution.

For those who have proprietary Gerber files on hand, they need only export them through the Advance Circuit website’s free PCB file check software. The FreeDFM program quickly and clearly evaluates printed circuit board design files, and then the online software reviews them and has the ability to automatically correct issues. It then sends a report itemizing any “Potential Showstoppers,” as well as providing accurate details of the issues that the software both identified and then fixed.

The clients who opt to use it will also receive a discount when they run the designs in advance of submitting them to the team.

This troubleshooting system requires exporting files from the Gerber program and then uploading online. The software is supplied for free but must be run through the site. Once an email is registered (this is for results to be sent instantly), it takes moments for the review, quote, and a discount offer to appear along with a link to the PDF file outlining the issues and repairs done.

Anyone involved in PCB design and manufacturing over the years knows that changes to the industry have made it impossible for most clients to tour a facility and meet with the fabricators to discuss any avoidable or common errors. This was once a strong troubleshooting tactic, but with companies in all corners of the globe making PCBs, that face to face interaction is no longer viable.

We recognize the hazards in this system and make a long list of resources available to our clients in order to help them prevent the creation of a batch of unusable PCBs or other products. We want to help clients avoid the enormous financial impact to their businesses this might cause.

The design phase of a project is a most crucial time, and so we offer free Gerber file reviews, corrections, and reporting. We also provide clients with free use of our unique and exclusive PCB Artist software. This offers a long list of features, including unrestricted design capabilities with a 28 layer limit, a controlled auto-router function, multi-page schematics, and more. It helps clients to avoid unnecessary design flaws, and though it is not the same as the Gerber options, it comes with a full array of free tutorials that teach even inexperienced designers how to make flawless files for production.

Enjoy Error-Free Design with Advanced Circuits

The high-quality design resources available on our website prove our commitment to client satisfaction and success, but we also deliver such benefits as never subbing out our work, skipping unnecessary tooling fees on orders adhering to standard specs, 24-hour tech support as well as customer support (meaning a CAM engineer is always available), no minimum orders and the BEST ON-TIME SHIPPING RECORD in the industry. Currently, we are shipping 50% of orders early! In fact, we ship Standard Spec orders on time or they’re FREE!

Don’t worry that Gerber files might cause costly errors – use the free resources available from Advanced Circuits!

Below is an example of a Gerber file:

Checking for Possible PCB Fabrication Issues

Advanced Circuits has developed a free online tool, FreeDFM, to ensure your PCB’s Geber files are complete and free of manufacturability issues before you send your files to your PCB fabricator. After you have exported your Gerber files from your PCB design software of choice, you will want to make sure the Gerber files are compressed into a .Zip folder before uploading the files to FreeDFM.

First, make sure you are familiar with the common Gerber file extensions. You will need to specify each layer to ensure the check is done correctly. Common Gerber file extensions include:

• pcbname.GTL – Top Copper
• pcbname.GTS – Top Soldermask
• pcbname.GTO – Top Silkscreen
• pcbname.GBL – Bottom Copper
• pcbname.GBS – Bottom Soldermask
• pcbname.GBO – Bottom Silkscreen
• pcbname.TXT – Drills
• pcbname.GML/GKO – Board Outline

Next, FreeDFM will analyze each file to ensure that you are not missing any required files for manufacturing and will also for things that will cause issues in the manufacturing process or overall functionality such as inadequate Soldermask clearance, missing drill hits, line width and other issues.

Once the tool has completed the analysis of your Gerber files, you will receive a comprehensive report of all possible manufacturability issues found within minutes in your email inbox automatically and 100%. Being able to identity these issues prior to sending the files to the manufacturer saves you time by avoiding production holds, and also saves you money by receiving the design as intended on your first run.

Below are each of the items that FreeDFM checks for on each upload:

Complete ZIP Files 

1. Gerber file for each copper layer
2. Gerber file for each soldermask layer
3. Gerber file for each silkscreen layer
4. Excellon or Gerber drill file

Inner Plane Layers 

1. Spacing
2. Trace width
3. Annular ring
4. Inner clearance (drill to feature)
5. Thermal reduction

Outer Layers

1. Spacing
2. Trace width
3. Annular ring

Drill

1. Double hits
2. Missing hits

Inner Signal Layers

1. Spacing
2. Trace width
3. Annular ring
4. Inner clearance (drill to feature)

Soldermask

1. Undersized clearances
2. Missing clearances

Silkscreen

1. Line width

After each file Gerber file check is completed, FreeDFM will also send you a discount code that saves you up to $100 off your next PCB order with Advanced Circuits. To learn more about our FreeDFM software, click here.