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.

It also opens up the door to the risk of losses due to flaws in the PCB design. Even when top-tier PCB design software is used by a skilled expert, there can always be mistakes that a production team can recognize. The “no-touch” approach used by most subcontractors, though, allows for glitches because files are often received and run without evaluation.

The good news is that some domestic PCB manufacturers have the ability to offer one-stop production, including access to free, premium PCB design software, along with expert evaluative services.

PCB Design Software to Ensure Optimal Results

Advanced Circuits provides customers with PCB design software, and rates as one of the most well-known companies in the PCB and prototype assembly industries. We handle PCB manufacturing (fabrication) and assembly, but it is often our PCB design software and expert support that sets us far apart from the crowd.

A one-stop shop with more than two decades in the industry, we provide customers with exclusive services that support, facilitate, and improve any project. The resources available for the PCB design process include the following.

Free PCB Layout Software – PCB Artist – Whether novice or expert designers, customers are often delighted by the entirely complimentary access they receive 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, it is a noted printed circuit board design tool throughout the industry.

Free PCB File Check – Whether or not the free PCB Artist software is used, there is also the FreeDFM program that enables clients to run a free and fast design assessment. The software uses PCB design software files uploaded into the system and then evaluates them fully. The program ensures files feature all essential data, automatically corrects some issues, and provides an easy-to-read and use report. Clients using it also enjoy a discount when they run the designs in advance of submitting them to the team.

If a customer is using Gerber format files, the PCB design software and File Check program can still be put to use. There are free uploading tools, and it takes only the submission of a client email to obtain the full evaluative report. It takes only minutes, and a quote, discount code, and link to the PDF of the results will appear.

End Problems Using PCB Design Software

Worried that you are going to have to relearn the use of PCB design software to enjoy the free tools and resources…as well as enjoy all of those benefits? Don’t be! The PCB Artist software comes with printable tutorials and video options that take even the extreme beginner through the complex process of PCB design and manufacturing. And there are experts on-call 24 hours a day to help.

Additionally, on top of the free file review software, every single order receives a free engineering file review before the fabrication process is initiated. What is this? An actual engineer examines the file and guarantees that customers never experience the kind of financially harmful outcomes they might have received via the more common no-touch services from outsourced work. Rather than an easily correctable design flaw allowed to go through and ruin a batch, the trained eye will detect issues and correct them before a project begins.

And, while the free PCB design resources made available on our website is enough to demonstrate why we are a preferred provider, there are many additional reasons to use and order through the PCB design software, including:

• No tooling charges – When an order features Standard Specifications, we’re always glad to eliminate tooling charges and cancel out such fees on reorders of Standard Spec as Custom Spec items.
• We are NOT a broker – Advanced Circuits never subcontracts work. Instead, we rely on our top-of-the-line, 62,000-square-foot facility that guarantees the kind of quality and speed most want but don’t always receive.
• 24-hour support – Customer service around-the-clock is great, but we 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 and get answers about the free PCB design software or PCBs, in general.
• 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 use.
• Best shipping record – Advanced Circuits has the best on-time shipping record in the industry.

Partner with Advanced Circuits for Error-Free PCB Design

Don’t spend a moment worrying about learning curves and other similar struggles for our free design tools. They are easy to use and include tutorials. Instead, get ready for a far more efficient design process, simple ordering, and discounted pricing. There are so many reasons to choose Advanced Circuits, and as you have seen, we go well beyond the free PCB design software. We ensure that any designs (whether received as Gerber files or another format) are without easily correctable mistakes. This saves time and money while keeping your firm on schedule. The free evaluation resources available include engineering reviews, and we make engineers available around-the-clock to help with any issues or questions.

It is difficult to beat this approach to PCB design and production, and with guarantees that orders arrive when scheduled (or they are free), it makes good sense to get in touch with Advanced Circuits and get your project started today.

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.

In this post, we discuss the basics of printed circuit board Gerber files.  For more detailed information about Gerber file generations and our requirements, click here.  For more PCB design and manufacturing resources, visit our PCB Engineering & CAM Resources page.

What are PCB Gerber Files

A Gerber file is basically an image of a PCB. It showcases each individual layer as it appears throughout your circuit design.  Gerber files represent copper layers images, solder mask, legend, and drill and route data helping to simplify the process of seeing how the circuit board should be fabricated.  The Gerber files also contain attributes that provide meta-information about these images, such as whether a graphics object is and SMD pad, a via pad,  a fiducial, or any other type of element.

Multiple programs have the ability to read a Gerber file format due to its simplicity, yet detailed descriptions of its contents. They additionally assist in locating potential issues and debugging of the circuit design when uploaded to our FreeDFM file check tool. When submitting a Gerber file, it is wise to send a straightforward text (.txt) file with the explanation of the requirements that may not appear in the file as a note to the PCB manufacturer.

What’s Included in PCB Gerber Files

When exporting the set of Gerber files for your PCB design, you will notice there is a set of individual files with different extensions which should be saved as a zipped folder to send over to the PCB manufacturer.  These files are the following elements of your circuit board design:

• Top Silkscreen
• Top Soldermask
• Top Copper
• Top Solderpaste
• Inner Copper
• Bottom Copper
• Bottom Soldermask
• Bottom Silkscreen
• Bottom Solderpaste
• NC Drill
• Non Plated Drill
• Slots
• Drawing/Other

When submitting your files for PCB fabrication, you will need to map your files (match) to the elements mentioned above.  Common file name extensions are listed in the image below.