Refine repository structure for KiCad 9 optimization
- Add dedicated /kicad/ directory with organized subdirectories for libraries, schematics, gerbers, plots, and backups - Create comprehensive KiCad 9 library structure (symbols, footprints, 3D models) - Add manufacturing-ready directories for production files (gerbers, drill, pick-and-place) - Update all README files with KiCad-specific documentation and workflows - Add KiCad-optimized .gitignore file for proper version control - Create KICAD-PROJECT-TEMPLATE.md comprehensive usage guide - Add hardware assembly documentation and BOM management - Include detailed manufacturing file generation instructions - Add docs structure with design-notes and user-manual directories - Provide complete workflow from design to manufacturing with quality checklists
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# /manufacturing/gerbers
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Final production Gerber files for PCB fabrication.
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## Purpose
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This directory contains the final, production-ready Gerber files that will be sent to your PCB manufacturer. These files define all the copper layers, solder mask, silkscreen, and board outline.
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## File Types
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- **`.gbr`**: Gerber files for each PCB layer
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- **`.gbrjob`**: Gerber job file (KiCad 6+) with layer stack information
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- **`.zip`**: Packaged files ready for manufacturer submission
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## Standard Gerber Files
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```
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gerbers/
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├── ProjectName-F_Cu.gbr # Front copper layer
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├── ProjectName-B_Cu.gbr # Back copper layer
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├── ProjectName-In1_Cu.gbr # Inner layer 1 (4+ layer boards)
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├── ProjectName-In2_Cu.gbr # Inner layer 2 (4+ layer boards)
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├── ProjectName-F_SilkS.gbr # Front silkscreen
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├── ProjectName-B_SilkS.gbr # Back silkscreen
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├── ProjectName-F_Mask.gbr # Front solder mask
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├── ProjectName-B_Mask.gbr # Back solder mask
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├── ProjectName-F_Paste.gbr # Front solder paste (SMT)
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├── ProjectName-B_Paste.gbr # Back solder paste (SMT)
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├── ProjectName-Edge_Cuts.gbr # Board outline/edge cuts
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├── ProjectName-job.gbrjob # Gerber job file
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└── ProjectName-Gerbers-v1.0.zip # Packaged for submission
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```
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## Generating Production Gerbers
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1. Open your final PCB design (`.kicad_pcb`)
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2. **File → Fabrication Outputs → Gerbers**
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3. Configure settings:
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- **Output directory**: `manufacturing/gerbers/`
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- **Plot format**: Gerber
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- **Include layers**: All copper, mask, silk, paste, edge cuts
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- **Options**: Check "Use Protel filename extensions" if required
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4. Click **Plot**
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5. Click **Generate Drill Files** (saves to `/manufacturing/drill/`)
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## Quality Control Checklist
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- [ ] All required layers present
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- [ ] Board outline properly defined
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- [ ] No missing copper connections
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- [ ] Silkscreen doesn't overlap pads
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- [ ] Solder mask openings correct
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- [ ] Component references visible and readable
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- [ ] Drill holes align with pads
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- [ ] File sizes reasonable (not empty or corrupted)
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## Manufacturer Requirements
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Different manufacturers may require specific settings:
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- **File format**: RS-274X (standard)
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- **Units**: Millimeters (preferred) or inches
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- **Zero suppression**: Leading zeros suppressed
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- **Coordinate format**: 3.6 (mm) or 2.5 (inches)
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- **Aperture format**: Embedded apertures (standard)
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## Pre-submission Verification
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1. **Gerber Viewer**: Use KiCad Gerber Viewer or online tools
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2. **Layer Stack**: Verify correct layer order
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3. **Drill Alignment**: Check drill holes align with pads
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4. **Dimensions**: Verify board size and hole sizes
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5. **Manufacturer Check**: Use manufacturer's online Gerber viewer
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## Common Issues to Avoid
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- Missing edge cuts layer
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- Incorrect drill file format
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- Silkscreen over pads
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- Missing solder mask openings
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- Incorrect layer naming
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- Empty or corrupted files
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## Packaging for Submission
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Create a ZIP file containing:
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- All Gerber files (`.gbr`)
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- Gerber job file (`.gbrjob`)
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- Drill files (from `/manufacturing/drill/`)
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- README with specifications
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- BOM (from `/hardware/bom/`)
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## File Naming Convention
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Use consistent naming that matches your project:
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- `ProjectName-LayerName.gbr`
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- `ProjectName-v1.0-Gerbers.zip`
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- Include version numbers for tracking
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