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.

Why should turnkey PCB assembly be a challenge? There are many steps involved. Just consider a few of them:

• Initial design
• Output to design for manufacturing or DFM checks
• Film creation
• Mapping of copper paths
• V-scoring
• Testing, and all of the phases between and after

Not surprisingly, any firm that offers same-day turnarounds for turnkey PCB assembly seems like an impossible thing, but at Advanced Circuits, we offer just that, and more.

A One-Stop Turnkey PCB Assembly, Design and Shipping Shop

We offer more than 25 years in the circuit boards industry and rank among the largest of the one-stop solutions for manufacturers in need of prototypes, stencils, supplies, and turnkey PCB assembly. We operate within a facility that includes tens of thousands of square feet of production space and offer clients a turnkey PCB assembly system that includes everything from design testing and submission to packing and shipping.

We offer clients such vital services and options as:

• One day PCB – We are one of the few PCB makers that can manufacture and assemble circuit boards and ship them out in as little as a single day.
• Full support – Unlike many other manufacturers, our team works with orders of any size, every step of the way. We begin with a quote based on initial design uploads, and take a project to final production and turnkey PCB assembly phases.
• Quality – Our design process is not of the “no-touch” variety where the designs are sent in and run into production right away. Every single order (whether one-off or thousands of PCBs) gets our full CAM review, as well as visual inspections of the final circuit boards produced.
• Transparent pricing – Also unlike many other producers, we do not ask for stenciling fees, setup fees, and other hidden, but ultimately unnecessary, charges on turnkey PCB assembly projects.

We are truly a one-stop system, ensuring a seamless process under one roof. Clients’ orders or projects remain in the hands of our engineers from beginning to end, and even before, as we have 24-hour service offered by authentic CAM engineers who take questions at all hours. Without any outside vendors (we are not a broker) and with production and full turnkey PCB assembly in a single space, there are almost no risks of delays, problems, and mistakes.

What We Include in Turnkey PCB Assembly

The speed and ease offered by a turnkey PCB assembly team are invaluable, but we also make some incredibly handy resources available too.

• PCB Artist Software – The cost of PCB design software is part of doing business, and it can be a huge expense. Advanced Circuits’ clients enjoy free use of our proprietary design software (an industry best) in an unrestricted format and entirely for free. It downloads to the desktop (Windows only at this time) and offers up to 28 layers in a single design. The program has over 500k parts from which to choose, integrates a controlled auto-router function to speed up design processes, and offers multi-page schematics for more complex projects. With a complete library of tutorials to train those using the program, there is almost no learning curve and even if errors are made, there are steps to the turnkey PCB assembly process that catch mistakes before
• Ordering through the software – When a client runs the proprietary software available through the site, we also provide them with a discount for ordering through it at the same time. Designs still get a CAM engineer review and crucial checks for errors, too.
• FreeDFM – For those already using a CAM program, turnkey PCB assembly is still supported by this design testing option. Files are imported as Gerber files (industry standard) and then loaded to the online software. This will review the entire file, correct any problems, and generate a report indicating changes or potential problems.
• No minimum orders – Whether a client needs a prototype or a large run, there’s no worry about minimums, ever.
• CAM Engineer Evaluations – All products are evaluated by one of our in-house engineers long before production begins, to spare clients any costly mistakes.
• Customers get authentic tech support – We go beyond basic customer support and offer turnkey PCB assembly clients the opportunity to troubleshoot with the help of a CAM engineer available 24 hours a day.
• Premier shipping – Any turnkey PCB assembly orders come with the BEST ON-TIME SHIPPING in the industry, and we are now shipping 50% of orders early! In fact, we ship Standard Spec orders on time or they’re FREE!

No Outsourcing with Advanced Circuits: We Proudly Produce & Stand Behind Our Work

It is a frustrating truth that most manufacturers face the risk of outsourcing on almost anything they use or buy. Outsourcing is no longer limited to customer service and other phone service options alone, and if it is turnkey PCB assembly that is in question, the risks of trouble increase with outsourcing. From errors or flaws in the design process, to manufacturing glitches that result in wasted money and time, it is unwise to look to brokered or outsourced solutions for a turnkey PCB assembly process.

Working with Advanced Circuits means buyers get the kinds of hands-on results that are so important and desirable. With us, all circuit board designs pass through a series of rigorous examinations long before production begins. We are not a broker but are instead a reliable one-stop solution; making everything in-house, eliminating production problems and supplying turnkey PCB assembly and results required for success.

However, the creation of PCBs with SMT manufacturing is quite complex and demands the use of advanced tools and technologies. DFM, or design for manufacturing, as an example, is the “coupled” process that integrates the basics of the PCB and takes into consideration the SMT manufacturing phases as well as the functionality of those SMT processes.

Will the design work as is or will there be a reworking of the PCB necessary? This is one of the major questions asked at the preliminary or prototyping phase, and often the SMT manufacturing component takes the back seat. However, as a design makes its way through the approval processes, SMT manufacturing has to enter the equation. Not only because it is essential to the actual function of the end product, but because it is such a cost-effective measure when hole-drilling can be eliminated.

The benefits of opting for SMT manufacturing include:

• Cost-cutting – The time and complexity of drilling is eliminated when surface mounting can be used instead
• Capabilities increased – The weight of a PCB that uses SMT manufacturing rather than drilling and soldering pastes means that the capabilities are improved, too. The era of the smaller and smaller device means that this design capability can open many previously closed doors.
• Automation – It makes sense to leverage the ability to mass-produce PCBs that retain performance and quality, and SMT manufacturing is a key approach to consistency when producing in mass quantities.

Of course, when considering SMT manufacturing, it also means being able to simultaneously ensure that the design is easily produced and effective. This is where Advanced Circuits can step in and make all of the difference. We have a nearly flawless system that alleviates design flaws in the pre-production process, and helps to cut down on rework that is often the bane of SMT manufacturing.

PCB and SMT Design Resources Bring Optimal Outcomes

Advanced Circuits is a well-known name in the PCB and Prototype Assembly industries. We can handle PCB manufacturing (fabrication) and assembly, including SMT designs.

We are a full-service provider with more than two decades in the field, and give clients exclusive services that support a project of any complexity or simplicity – whether a one-off prototype or a design with SMT and mass production requirements. The resources we make available for them include:

PCB Artist – Customers of all design levels love the free access we provide to this innovative PCB design software. Unrestricted, it is capable of up to 28 layers and includes more than 500k parts, a controlled auto-router function, multi-page schematics, and more. Easy to use and 100% free, it is also noted throughout the industry as the very best PCB design tool.

FreeDFM– This software enables clients to run a free and fast design assessment. It works easily and simply by using uploaded design files, then the program ensures files feature all essential data, automatically corrects some issues, plus provides an easy to read and use report. Using it also comes with a discount on the work if the designs are submitted through the software. This software uses Gerber format, but it takes only minutes, then a quote, discount code and link to the PDF of the results will appear.

All orders undergo a mandatory engineering file review before the fabrication process is initiated. This guarantees that glitches part of the typical “no-touch” approach will not occur, and that time and money will never be wasted by design flaws or manufacturing problems (i.e. rework issues) that could have been avoided.

End Reworking, Delays, and Clunky Design

Worried that learning the free software will take too long or ask too much before showing you how to integrate SMT into your designs? No need to worry, because the PCB Artist software we offer comes with printable tutorials and video options that walk even a beginner through the complex process of PCB design and manufacturing. And when the files are ready, the PCBs can be ordered directly through the software.

And, while the free PCB design resources made available on our site are enough to make us a premier and preferred provider, there are many other reasons to buy PCBs that incorporate SMT manufacturing from Advanced Circuits, including:

• No minimum orders – There are no minimum lot requirements, meaning that clients are not forced to invest in huge orders with more PCBs than might be needed. Prototyping is an option – even with SMT features.
• 24-hour support – Around the clock customer service features live tech support that allows design teams to speak directly with a CAM engineer at any hour of the day or night.
• No tooling charges – When an order features Standard Specifications, we are glad to waive tooling charges and always cancel such fees on reorders of Standard Spec as Custom Spec items.
• Not a broker – We never sub out our work bt instead count on our top of the line, 62k square foot facility and that guarantee the kinds of quality and speed most want but cannot always receive.
• Best shipping record – Advanced Circuits has the BEST ON-TIME SHIPPING RECORD in the industry, and is now shipping 50% of orders early! In fact, we say we “put our money where our mouth is . . . and we ship Standard Spec orders on time or they’re FREE!”

With so many reasons to choose Advanced Circuits, and with all of our free PCB design tools and resources available, it makes good sense to get in touch with us today. Our instant quotes and easy order tracking mean that a manufacturing or electronics firm of any size can obtain top quality PCBs designed flawlessly and to precise specifications. We also make SMT Solder Paste Stencils available as part of a NEW complete prototyping stencil kit for those who want to do one-off or “by hand” SMT manufacturing and design.

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.

After all, prototyping means designing something new, having the unit made, addressing flaws or design issues, and only then sending it into production. There is always the risk that a design flaw might be overlooked, and working with subcontractors can actually increase such concerns. All of these factors are why so many people will avoid the entire process and stick with a less than desirable solution. Settling for a stock or standardized design, however, is not a forward-thinking approach.

The good news is that there is no such thing as one size fits all circuit board design. Advanced Circuits, a top industry manufacturer, offers an array of resources capable of empowering firms with even limited budgets to upgrade, customize and enjoy flexibility. Of course, it helps to have a bit more clarity on just what is available generally before delving into the options in custom printed circuit board design.

The General Options in PCB Design

A simple or basic list of the options for PCB design include:

• Single Layer
• Double Layer
• Multi-Layer
• Rigid
• Flexible
• Flex-Rigid
• High-frequency
• Aluminum-Backed
• Full Spec
• LDI
• Oversized
• Heavy copper
• and more

Clearly, this means an array of production capabilities has to exist and come in at the right price and quality points to meet such a diversity of potential needs or designs. Advanced Circuits can supply almost any type of production capability and facilitate premium circuit board design that goes along with it.

Optimal Circuit Board Design from Advanced Circuits

In addition to there being such a diversity of PCB types, there will be many design needs. For example, printed circuit board design may involve only a single layer, or it might be two-sided, but the complexity of modern electronics may necessitate up to 28 layers incorporated into a design, and each layer will require synchronous interaction. This means there is always room for error in circuit board design, and the option for multiple sets of eyes and various levels of expertise may prove remarkably beneficial and cost effective.

Because of that, Advanced Circuits has created a system of tools, resources and services that are all meant to facilitate optimal circuit board design. The resources and services include:

• Expert advice – In addition to classic customer support, our team includes access to CAM engineers 24-hours each day. Customers are able to phone in design and engineering questions and have them answered by a professional engineer.
• Expert Reviews – CAM engineers also conduct a thorough review of each design as it is about to enter into the production process. This is a final check and guarantees that there are no issues that might lead to a negative outcome.
• Full and free design support – In addition to expert engineers, Advanced Circuits offers industry best software meant to enable superior design. PCB Layout Software – PCB Artist features a library of more than 500k tools and components that can be built into designs of up to 28 layers. It can control auto router functions, multi-page schematics, and more. It is offered in an unrestricted format, meaning it comes at no cost but allows top-of-the-line design options.

After that, clients are able to use the FreeDFM program, which requires an export to Gerber file format and upload to the Advanced Circuits website. Once that fast and easy process has been completed, the client can enjoy a full evaluation of the PCB design. A report is emailed to the provided contact and it explains which flaws were discovered, remedied and what were targeted as potential showstoppers, but left in place.

As any professional knows, PCB design is the key factor in the whole process. A single error makes a prototype a failure or an entire batch of PCBs useless. It could lead to enormous wastes of time and resources. Yet, the entirety of the process does not begin and end with design. There are other factors that impact whether or not printed circuit board design is as successful or effective as it could be.

A lot of it has to do with the approach the producer takes to the process. Advanced Circuits ensures that its clients experience a process that empowers their success, from the design phase to assembly. This means that we:

• Keep it in house – Our enormous production facilities are Advanced Circuits’ way of proving commitment to the entire process. We are able to work with design files and a team of engineers that ensure files are complete and appropriate to the client’s goals. However, we also handle fabrication and assembly on the premises, too. While so many modern manufacturers are “no touch,” we are most distinctly hands-on and manage every aspect of a project.
• Comprehensive website – The ease with which clients can get the tools needed and then use them effectively is only one part of our service. We also provide instant quotes, unique client pages where previous orders and simple reorders are possible, stencils, file uploading, order tracking, and “through software” orders. Design something using the free PCB Artist software, and order it once it has cleared the CAM or free evaluation services. This also gives clients a discount on any standard spec orders.
• Tooling fees – Many manufacturers impose a tooling fee on standard spec orders, but clients can count on a fee-free process with Advanced Circuits. Even if a custom spec orders is re-ordered, the tooling fees are cancelled out.
• No minimum orders – Budgets are protected by Advanced Circuits’ no minimum order requirements, and whether it is a single board with a single day of turnaround time or a huge order, the quantity is in the hands of the clients.

Advanced Circuits Removes the Challenges in the PCB Production Process

The PCB design and production process is full of potential challenges and issues. Advanced Circuits clients receive their specific designs without breaking the budget, slowing production times or wasting resources. Whether clients need one PCB, small batches or larger orders, Advanced Circuits can produce quality printed circuit boards to client requirements.

To get an instant PCB quote and learn more about our quick turn capabilities, review our standard and custom spec PCB page.

No Touch PCB Manufacturing Leads to Disaster

The modern world has made a sudden and rather massive shift into the online, mobile, and web-based model. As an example, in the past, PCB manufacturing meant a company would usually pay a visit to a PCB manufacturing facility or headquarters to work directly with the team designing or making such crucial components. The fabricators and the client would have to interact several times in order to guarantee that there were no design flaws and that the entire project (from prototype to batch manufacturing) proceeded exactly as expected.

Today, this is a far outdated system and for many companies in need of small to large batch PCB manufacturing, the process involves overseas and no-touch providers. If domestic, it might still mean very little interaction and the guarantees that such exchanges bring. It might even be that the PCB manufacturing and assembly are done in different locations or by different providers.

This can prove quite problematic because it might mean that client expectations are left unmet or even unknown by the manufacturer. It can mean that errors in design go unnoticed until the post-production period when the PCB is meant to be put to use in the final product, but fails to yield the results necessary. And this would mean that the batch of PCBs is unusable; production would be halted, and budget and resources wasted.

Fortunately, the team at Advanced Circuits has created a system and perfected it over the course of more than twenty years. Offering PCB manufacturing – fabrication and assembly, prototypes, and more, we can facilitate projects from start to finish while overcoming many of the potentially harmful issues outlined above.

Free Resources Ensure Fail-Proof PCB Manufacturing

Advanced Circuits proves that the advent of technologies that make everything possible through the Internet instead of real-world exchanges may not be a bad thing. We manage this by using a system of free and effective resources that enable clients to get the very best in PCB manufacturing outcomes, and all done entirely online. Here’s how:

• PCB Artist Software – Free to download and use in its unrestricted format, this industry-best software has more features than anything else on the market, and yet it is also provided in an unrestricted format with more than 500k parts and components in the customized library. Using it also means that some preliminary glitches are erased and that design is streamlined through the presence of a controlled auto router function, digital schematics, and more. Additionally, the use of the software allows clients to enjoy discounted pricing when submitting as a Standard Spec order through the program.
• File Review Software – Our FreeDFM software is another free to use resource that takes the common Gerber file (exported from the client’s software and then uploaded to the site), where it then evaluates a design and ensures that all essential data is included, adjusts or corrects design flaws, and issues a report that itemizes any potential showstopper errors, and identifies what the software was able to address and fix.
• CAM Engineer Review – Before any PCB begins the production process, the designs and/or prototype are reviewed in house by a team of Advanced Circuits’ CAM experts. Advanced Circuits also features live tech support provided by these same CAM engineers at any hour of the day or night, which allows clients to pose any questions or concerns and get a skillful and well-informed answer.
• Through software ordering – When a client has decided that the design is entirely free of errors and that it is ready for entry into the full production cycle, the free software allows them to go right ahead and make that order. When it is submitted in Standard Specifications it also enjoys no added tooling fees, and if it is a Custom Specifications order that has already been produced and enters as Standard Specifications, that same tooling fee deduction is applied.

Regardless of the size of a company or the complexity of a project, the cost of producing PCBs can be surprising. Investing in the necessary software and technologies, having the right teams to understand what is needed, and then seeing the production process completed properly can all add up. After all, even the simplest boards must work their way through key phases that include:

• Design – Is there a team to manage design? What sort of software is in use and what are the costs associated with it? Is there a dedicated team meant to evaluate the blueprints to detect errors? What costs are associated with the prototype? How fast can it be completed?
• Evaluation – Whether designs are printed on films or digitally, someone must troubleshoot them. Is this an outsourced step? Is it something that the manufacturer is counted on to provide? Has this been integrated into the production plan?
• Production – Is this going to occur in one facility with all of the substrate creation, layer building, UV hardening, copper removal, laminating, pressing, drilling, imaging, etching, soldering, and inspecting done by a solid team?

Avoid Costly Errors – Trust Advanced Circuits for a Premium PCB Production Experience

There are too many points in the PCB manufacturing process where disaster might occur, and it makes sense to avoid any potential risks by working with a one-stop shop. This is precisely what the team at Advanced Circuits delivers. Providing the tools required from start (including high end design software) to finish, our team can deliver. No minimum orders and professional reviews guarantee that modern innovations don’t get in the way of a premium production experience and outcome.

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.

This is also why the same-day turnaround times that a firm like Advanced Circuits offers seem too good to be true, even though they are not.

One-Stop Printed Circuit Boards Shop

With more than 25 years in the circuit boards industry, we are one of the largest and few one-stop solutions for those in need of premium circuit boards and prototypes. With tens of thousands of square feet of production space, we offer clients an in-house PCB assembly system from start to finish.

Our capabilities include:

• One day PCB – We are one of the few PCB makers that can manufacture and assemble circuit boards and ship them out in as little as a single day
• Full support – Unlike many other manufacturers, our team works with you every step of the way. We begin with a quote based on initial design spec uploads and walk all clients through to the final production and assembly phases.
• Quality – While many in the PCB industry approve of Advanced Circuits’ array of design resources, they also appreciate the inspection process that begins with a full CAM review before any manufacturing begins, as well as visual inspections of the final circuit boards produced.
• Clear pricing – Also unlike many other producers, we do not ask for stenciling fees, setup fees, and other hidden, but ultimately unnecessary charges.

Keep in mind that we are also a chosen maker of circuit boards because of our one-stop system. This ensures a totally seamless process that occurs under a single roof and remains consistently in the hands of our designers and engineers. Without any outside vendors and with the option for production and assembly in a single space, there will be fewer risks of delays, problems, and errors.

Beyond In-house Production and Assembly of Circuit Boards

While the convenience and speed that comes with in-house production and assembly of printed circuit boards cannot be overlooked; the capabilities that Advanced Circuits makes available ensure a much more substantial list of benefits can be enjoyed.

For one thing, we impose no minimum orders, making us an ideal solution for small to midsized firms in addition to larger manufacturers. We also make design, even for the novice teams, remarkably foolproof. We do this through:

• CAM engineer evaluations – All products are evaluated by one of the in-house engineers long before production begins in order to spare clients any costly mistakes.
• Free design software – The cost of PCB design software is part of doing business, but the Advanced Circuits proprietary and exclusive PCB Artist software is available in an unrestricted format and entirely for free. It is a free download to a client’s desktop (Windows only at this time) and is capable of up to 28 layers in a single design. The program has over 500k parts from which to choose, integrates a controlled auto-router function to speed up design processes, and offers multi-page schematics for more complex projects. With a complete library of tutorials to train those using the program, there is no reason not to take advantage of it (and the discounts given to clients who opt for the use of our free software).
• Free evaluation software – For those already using a CAM program of their own, the option for FreeDFM allows the manufacturing quality of a design to be tested. The files are exported in a Gerber format and loaded to the online software. This will review the entire file, correct any glitches and generate a report indicating changes or potential problems.
• Customers get tech support – And while it is great to have customer support around the clock, few PCB firms will offer their clients an opportunity to troubleshoot with the help of a CAM engineer. However, Advanced Circuits does have experts of this kind available 24 hours a day.
• Ordering through the software – When a client runs the proprietary software available through the Advanced Circuits’ website, they also have the choice of ordering through it at the same time. They still get that CAM engineer review and the crucial checks for errors, but they can use the software to make the order, too. And when they do, they receive a discount code as an incentive.

We live in a world of outsourcing everything. It is no longer just customer service and other phone service options that are sent overseas. This can make for a lot of difficulties in the design process. Even when there are online solutions that make uploading your proprietary files easier than ever; the danger for grave mistakes presents too many risks involving time, money and reputation. That’s why so many companies choose Advanced Circuits for their PCB manufacturing and assembly.

When you work with Advanced Circuits, you get the kinds of hands-on interaction and attention that the modern world is so short on. Rather than the distinctly “no-touch” approach used by a lot of fabricators (who want to receive your pre-tested files and get to work), we are a distinctly hands-on service. We run the printed circuit boards through rigorous examinations before any part of production begins. Since we are not a broker but are instead that one-stop solution making everything in-house, it is assured that we do all we can to prevent problems.

We have quick turns services specialists with some of the fastest turnaround times and shipping. In fact, we have the BEST ON-TIME SHIPPING RECORD in the industry, and are now shipping 50% of orders early! In fact, we ship Standard Spec orders on time or they’re FREE!

When you want a flawless design process full of support and even corrections and adjustments that guarantee success, depend on the Advanced Circuits team to produce and deliver your order.

Gerber File Manufacturability Check

Advanced Circuits’ online tool, FreeDFM, offers a quick and easy way to check your Gerber files prior to submitting your order for manufacturing.  The free tool ensures that all of the design rules are satisfied and all required data is included in your Gerber files.  Checking your files can save you time by avoiding CAM holds after your order has been placed and it can save you money making sure your printed circuit boards are produced exactly as intended the first time.

How to Use FreeDFM

To use Advanced Circuits’ FreeDFM software, make sure that your Gerber files are placed in a single folder and compressed as a .Zip.  Upload your .Zip file to FreeDFM and provide the email address where you would like to receive the detailed report identifying any possible issues found.

Next, our FreeDFM software will automatically identify the files based on the standard naming conventions of most EDA software packages.  You may also manually identify any of the files if the system was not able to match the file extension.  Click here to view a list of the most common Gerber file extensions file naming conventions.

Once you submit your file, Advanced Circuits’ FreeDFM software will perform the automated checks for your PCB design and send a detailed report outlining any possible manufacturability issues found in your Gerber files.  The report is sent directly to your inbox within minutes and it will contain the location and description of the issues along with a discount code for up to $100 off your next PCB fabrication order.

Below is an example of FreeDFM’s Report:

What Does FreeDFM Check For in Your Gerber Files?

Each time you submit Gerber files to FreeDFM, the software will perform all of the following checks:

Complete Gerber Files in .ZIP Folder

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