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
Final production Gerber files for PCB fabrication.
## Purpose
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.
## File Types
- **`.gbr`**: Gerber files for each PCB layer
- **`.gbrjob`**: Gerber job file (KiCad 6+) with layer stack information
- **`.zip`**: Packaged files ready for manufacturer submission
## Standard Gerber Files
```
gerbers/
├── ProjectName-F_Cu.gbr # Front copper layer
├── ProjectName-B_Cu.gbr # Back copper layer
├── ProjectName-In1_Cu.gbr # Inner layer 1 (4+ layer boards)
├── ProjectName-In2_Cu.gbr # Inner layer 2 (4+ layer boards)
├── ProjectName-F_SilkS.gbr # Front silkscreen
├── ProjectName-B_SilkS.gbr # Back silkscreen
├── ProjectName-F_Mask.gbr # Front solder mask
├── ProjectName-B_Mask.gbr # Back solder mask
├── ProjectName-F_Paste.gbr # Front solder paste (SMT)
├── ProjectName-B_Paste.gbr # Back solder paste (SMT)
├── ProjectName-Edge_Cuts.gbr # Board outline/edge cuts
├── ProjectName-job.gbrjob # Gerber job file
└── ProjectName-Gerbers-v1.0.zip # Packaged for submission
```
## Generating Production Gerbers
1. Open your final PCB design (`.kicad_pcb`)
2. **File → Fabrication Outputs → Gerbers**
3. Configure settings:
- **Output directory**: `manufacturing/gerbers/`
- **Plot format**: Gerber
- **Include layers**: All copper, mask, silk, paste, edge cuts
- **Options**: Check "Use Protel filename extensions" if required
4. Click **Plot**
5. Click **Generate Drill Files** (saves to `/manufacturing/drill/`)
## Quality Control Checklist
- [ ] All required layers present
- [ ] Board outline properly defined
- [ ] No missing copper connections
- [ ] Silkscreen doesn't overlap pads
- [ ] Solder mask openings correct
- [ ] Component references visible and readable
- [ ] Drill holes align with pads
- [ ] File sizes reasonable (not empty or corrupted)
## Manufacturer Requirements
Different manufacturers may require specific settings:
- **File format**: RS-274X (standard)
- **Units**: Millimeters (preferred) or inches
- **Zero suppression**: Leading zeros suppressed
- **Coordinate format**: 3.6 (mm) or 2.5 (inches)
- **Aperture format**: Embedded apertures (standard)
## Pre-submission Verification
1. **Gerber Viewer**: Use KiCad Gerber Viewer or online tools
2. **Layer Stack**: Verify correct layer order
3. **Drill Alignment**: Check drill holes align with pads
4. **Dimensions**: Verify board size and hole sizes
5. **Manufacturer Check**: Use manufacturer's online Gerber viewer
## Common Issues to Avoid
- Missing edge cuts layer
- Incorrect drill file format
- Silkscreen over pads
- Missing solder mask openings
- Incorrect layer naming
- Empty or corrupted files
## Packaging for Submission
Create a ZIP file containing:
- All Gerber files (`.gbr`)
- Gerber job file (`.gbrjob`)
- Drill files (from `/manufacturing/drill/`)
- README with specifications
- BOM (from `/hardware/bom/`)
## File Naming Convention
Use consistent naming that matches your project:
- `ProjectName-LayerName.gbr`
- `ProjectName-v1.0-Gerbers.zip`
- Include version numbers for tracking