Introduction
Exporting Gerber files from DipTrace is a crucial step in the PCB manufacturing process. This comprehensive guide will walk you through every aspect of generating accurate and manufacturer-ready Gerber files using DipTrace software, ensuring your PCB designs can be successfully manufactured.
Understanding Gerber Files
What Are Gerber Files?
Gerber files are the standard format used in the PCB industry to communicate design information to manufacturers. They contain specific data for each layer of your PCB design.
Essential Gerber File Types
| File Extension | Layer Type | Description |
|---|
| .GTL | Top Layer | Contains top copper traces and pads |
| .GBL | Bottom Layer | Contains bottom copper traces and pads |
| .GTS | Top Solder Mask | Defines areas where solder mask is removed |
| .GBS | Bottom Solder Mask | Defines bottom solder mask openings |
| .GTO | Top Overlay | Contains silkscreen information |
| .GBO | Bottom Overlay | Contains bottom silkscreen information |
| .GTP | Top Paste | Defines areas for solder paste application |
| .GBP | Bottom Paste | Defines bottom solder paste areas |
| .GKO | Board Outline | Defines the PCB edge cuts |
| .XLN/.TXT | Drill File | Contains drilling information |
Preparing Your PCB Design
Design Rule Check
Before exporting Gerber files, ensure your design meets all manufacturing requirements:
| Check Category | Parameters to Verify | Typical Values |
|---|
| Trace Width | Minimum trace width | ≥ 0.15mm |
| Trace Spacing | Minimum spacing | ≥ 0.15mm |
| Via Size | Minimum via diameter | ≥ 0.3mm |
| Board Outline | Edge clearance | ≥ 0.3mm |
| Text Size | Minimum text height | ≥ 1mm |
Layer Stack Configuration
| Layer | Standard Stack-up | Purpose |
|---|
| Top Overlay | First | Component markings |
| Top Paste | Second | Solder paste stencil |
| Top Solder Mask | Third | Solder mask layer |
| Top Copper | Fourth | Top electrical layer |
| Core Material | Middle | Substrate |
| Bottom Copper | Fourth from bottom | Bottom electrical layer |
| Bottom Solder Mask | Third from bottom | Bottom solder mask |
| Bottom Paste | Second from bottom | Bottom paste stencil |
| Bottom Overlay | Last | Bottom markings |
DipTrace Gerber Export Process
Basic Export Steps
- File Preparation
- Save your PCB design
- Run final DRC check
- Verify layer visibility
- Check component placement
- Export Settings Configuration
- Open Export Production Files dialog
- Select output directory
- Configure layer mapping
- Set export parameters
Export Parameters Configuration
| Parameter | Recommended Setting | Description |
|---|
| Units | MM | Metric units for consistency |
| Format | 4:4 | Four digits before and after decimal |
| Zeros | Leading | Keep leading zeros |
| Encoding | ASCII | Standard text encoding |
| Extension | .ger | Standard Gerber extension |
Layer Configuration
Essential Layer Settings
| Layer Type | Export Options | Notes |
|---|
| Copper Layers | Pads, Traces, Fills | Include all copper elements |
| Solder Mask | Inverse, Pads only | Check pad clearances |
| Silkscreen | Text, Components | Verify text readability |
| Paste Mask | Component pads | Check stencil requirements |
| Drill File | Plated, Non-plated | Separate drill files |
Advanced Layer Options
Copper Layer Settings
| Setting | Purpose | Default Value |
|---|
| Thermal Relief | Pad connection | Enabled |
| Clearance | Copper spacing | 0.2mm |
| Min Width | Trace width | 0.15mm |
| Polygon Pour | Fill type | Solid |
Advanced Export Settings
Aperture Configuration
| Aperture Type | Usage | Configuration |
|---|
| Round | Vias, round pads | Auto-generated |
| Rectangle | Square pads | Auto-generated |
| Oblong | Elongated pads | Custom defined |
| Custom | Special shapes | User defined |
Drill File Configuration
| Parameter | Setting | Description |
|---|
| Format | Excellon | Industry standard |
| Units | Metric | MM specification |
| Zeros | Leading | Include leading zeros |
| Tool Range | 0.2mm - 6.5mm | Common drill sizes |
Verification and Validation
Pre-Export Checklist
| Check Item | Verification Method | Common Issues |
|---|
| Layer Stack | Visual inspection | Missing layers |
| Drill Sizes | Size verification | Invalid sizes |
| Board Outline | Continuous path | Gaps in outline |
| Component Clearance | DRC check | Spacing violations |
| Text Legibility | Visual review | Undersized text |
Post-Export Verification
- File Completeness Check
- Verify all required files are generated
- Check file sizes are reasonable
- Confirm file extensions are correct
- Gerber Viewer Inspection
- Load files in viewer
- Check layer alignment
- Verify drill positions
- Confirm board dimensions
Troubleshooting Common Issues
Export Errors
| Error Type | Possible Cause | Solution |
|---|
| Missing Layers | Incorrect configuration | Review layer settings |
| Invalid Format | Wrong export parameters | Check format settings |
| Incomplete Files | Process interruption | Re-export files |
| Size Mismatch | Unit configuration | Verify unit settings |
File Validation Issues
| Issue | Symptom | Resolution |
|---|
| Misaligned Layers | Visual offset | Check origin point |
| Missing Features | Incomplete output | Review export settings |
| Drill Mismatch | Incorrect positions | Verify drill file format |
| Scale Problems | Wrong dimensions | Check unit configuration |
Best Practices
File Organization
| Category | Recommendation | Purpose |
|---|
| File Naming | Consistent convention | Easy identification |
| Folder Structure | Organized hierarchy | Better management |
| Version Control | Revision numbering | Track changes |
| Backup | Multiple locations | Data protection |
Quality Assurance Steps
- Pre-Export Preparation
- Complete design review
- Run final DRC
- Check layer visibility
- Verify component placement
- Export Process
- Use consistent settings
- Maintain organized structure
- Document special requirements
- Verify output files
Manufacturing Considerations
Manufacturer Requirements
| Requirement | Typical Specification | Notes |
|---|
| File Format | RS-274X | Modern Gerber |
| Drill Format | Excellon | Industry standard |
| Layer Names | Clear identification | Standardized naming |
| Archive Format | ZIP | Compressed package |
Production-Ready Package
| File Type | Purpose | Required |
|---|
| Gerber Files | Layer data | Yes |
| Drill Files | Hole information | Yes |
| README | Special instructions | Recommended |
| Drawing | Board dimensions | Recommended |
Frequently Asked Questions
Q1: What is the correct layer sequence for exporting Gerber files in DipTrace?
A1: The recommended layer sequence is: Top Overlay, Top Paste, Top Solder Mask, Top Copper, Internal Layers (if any), Bottom Copper, Bottom Solder Mask, Bottom Paste, and Bottom Overlay. Drill files should be exported separately in Excellon format.
Q2: How do I verify my Gerber files are correct before sending them to manufacturing?
A2: After export, use a Gerber viewer to check: layer alignment, presence of all required layers, correct board dimensions, proper drill hole locations, and component placement. Also verify that copper layers, solder mask, and silkscreen align properly.
Q3: What are the most common export settings mistakes in DipTrace?
A3: Common mistakes include incorrect units (metric vs. imperial), wrong number format (leading vs. trailing zeros), improper layer selection, and forgotten drill files. Always verify these settings before export and use the recommended 4:4 format with leading zeros.
Q4: Why are some features missing in my exported Gerber files?
A4: Missing features usually result from incorrect layer visibility settings, improper export configuration, or features being on disabled layers. Ensure all relevant layers are visible and properly configured in the export settings dialog.
Q5: How do I handle different drill sizes in DipTrace Gerber export?
A5: DipTrace automatically generates a drill file with all hole sizes. Ensure you export both plated and non-plated holes if your design requires them. The drill file should be in Excellon format with metric units for consistency.
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