b4l-project-template/manufacturing/gerbers

/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

Following FILE-NAMING-AND-VERSIONING.md standards:

• project-name_gerbers_v1.0.0_2024-08-04.zip - Complete Gerber package
• project-name_gerber-job_v1.0.0_2024-08-04.gbrjob - Gerber job file
• project-name_fabrication-notes_v1.0.0_2024-08-04.txt - Manufacturing notes

Individual Layer Files

• project-name-f-cu_v1.0.0.gbr - Front copper
• project-name-b-cu_v1.0.0.gbr - Back copper
• project-name-f-silks_v1.0.0.gbr - Front silkscreen
• project-name-edge-cuts_v1.0.0.gbr - Board outline

Versioning Strategy

• MAJOR: PCB layout changes, layer stack changes
• MINOR: Component placement changes, routing updates
• PATCH: Silkscreen updates, minor corrections