How to Convert Adobe Illustrator Files to Gerber for PCB Manufacturing

Adobe Illustrator is one of the most powerful vector design tools available, and plenty of designers use it for PCB artwork, custom board shapes, and detailed graphics. The problem? Illustrator doesn’t speak Gerber. It can’t export the manufacturing files that PCB fabs need.

I’ve worked with countless designers who create beautiful artwork in Illustrator only to get stuck when it’s time to actually manufacture the board. The good news is there are several reliable methods to convert Illustrator files to Gerber format. Some are straightforward, others require intermediate steps, but all of them work.

This guide covers every practical approach to converting Adobe Illustrator files to Gerber, from direct conversion tools to multi-step workflows through PCB design software.

Understanding Adobe Illustrator and Gerber File Formats

Before diving into conversion methods, understanding what makes these formats different helps you choose the right approach and avoid common pitfalls.

What is an Adobe Illustrator File?

Adobe Illustrator’s native format (.ai) stores vector graphics using Adobe’s proprietary structure. It supports complex features including layers, bezier curves, gradients, transparency, text, and embedded images. Illustrator files are designed for visual design work, not manufacturing.

Illustrator can also export to several interchange formats that become important for PCB conversion:

• PDF (Portable Document Format) – Preserves vector data and layers
• SVG (Scalable Vector Graphics) – Open standard vector format
• DXF (Drawing Exchange Format) – AutoCAD interchange format
• EPS (Encapsulated PostScript) – Legacy vector format

What Makes Gerber Files Different

Gerber is the de facto standard for PCB manufacturing. Each Gerber file represents exactly one layer of a circuit board and contains instructions for photoplotter equipment. The format works in absolutes: specific coordinates paired with defined apertures (shapes).

A complete PCB manufacturing package typically includes:

• Separate Gerber files for each copper layer
• Solder mask Gerbers (top and bottom)
• Silkscreen Gerbers (top and bottom)
• Board outline Gerber
• Excellon drill files for hole data

Key Differences Between Illustrator and Gerber Formats

Characteristic	Adobe Illustrator	Gerber Format
Primary Purpose	Visual design, illustration	PCB manufacturing
Curves	Native bezier support	Approximated with line segments
Layers	Flexible, unlimited	One file per PCB layer
Colors	Full color, gradients	Single polarity (dark/clear)
Text	Editable fonts	Must be converted to paths
Transparency	Supported	Not supported
Effects	Filters, blends, masks	Geometry only

Why Designers Use Adobe Illustrator for PCB Work

Despite the conversion challenges, there are legitimate reasons why designers choose Illustrator for PCB-related work.

Complex Artwork and Graphics

Illustrator excels at creating detailed graphics that would be tedious or impossible in standard PCB tools. Conference badges, artistic boards, and decorative panels often start life in Illustrator because of its superior drawing tools.

Custom Board Outlines

Organic shapes, decorative edges, and complex cutouts are much easier to design in Illustrator than in most PCB software. The pen tool and pathfinder operations make shape creation intuitive for designers already familiar with the Adobe ecosystem.

Brand Assets and Logos

Company logos typically exist as Illustrator files. Converting these to Gerber allows placement on silkscreen or copper layers without redrawing from scratch.

RF and Antenna Design

Some RF engineers prefer Illustrator’s precision tools for designing antenna patterns and microwave structures where aesthetic curve quality matters.

Adobe Illustrator to Gerber Conversion Methods

There are five main approaches to convert Illustrator files to Gerber format. Each has strengths depending on your specific needs.

Method 1: PDF Export with pdf2gerb Script

The pdf2gerb Perl script was specifically created for converting Adobe Illustrator designs to Gerber format. It’s free, open-source, and works directly with PDF files exported from Illustrator.

How it works:

The PDF and Gerber formats are structurally similar. Both use coordinate-based commands to move a “pen” and change line weights or apertures. pdf2gerb translates PDF commands to their Gerber equivalents.

Setting up your Illustrator file:

1. Create separate layers for each PCB layer (Top Copper, Bottom Copper, Silkscreen, Soldermask, Drill)
2. Use solid black for copper/ink present areas
3. For drill holes, draw a solid black circle (pad) with a solid white circle on top (hole)
4. Save as PDF, preserving layers

Running the conversion:

bash

chmod 755 pdf2gerb.pl./pdf2gerb.pl /path/to/circuit.pdf

The script generates Gerber and NC Drill files for each layer in the PDF.

Limitations:

• Doesn’t handle bezier curves well (convert to straight segments first)
• Requires careful layer setup in Illustrator
• Command-line tool may intimidate non-technical users

Method 2: PDF/PostScript to Gerber with ACE 3000

ACE 3000 from Numerical Innovations is a professional CAD translator that handles PDF and PostScript files from Illustrator. This is the recommended commercial solution for production work.

Workflow:

1. In Illustrator, export as PDF or PostScript (EPS)
2. Open ACE 3000 and import the file
3. Assign colors or layers to PCB layers
4. Export to Gerber and Excellon drill format

Advantages:

• Handles complex Illustrator files reliably
• Professional support available
• Includes fill and polygon handling
• Works with layer-based or color-based separation

Important note from Numerical Innovations: Using PDF/PostScript export from Illustrator works much better than DXF. Adobe’s DXF export creates problematic files with duplicate data that requires cleanup.

Method 3: DXF Export Through PCB Software

Illustrator can export to DXF format, which most PCB design tools can import. This creates a bridge between Illustrator and standard Gerber generation.

Step 1: Export DXF from Illustrator

1. Select artwork for export
2. File → Export → Export As → DXF
3. Choose AutoCAD R13/LT95 format for best compatibility
4. Check “Maximum editability” option
5. Position artwork at lower-left of artboard

Step 2: Import to PCB Software

Software	Import Method
KiCad	File → Import → Graphics (select DXF)
Eagle	Run ULP: import_dxf_polygons_v4.ulp
Altium	File → Import → DXF
DesignSpark	File → Import → DXF

Step 3: Generate Gerber Files

Once imported, use your PCB software’s standard Gerber export function.

Handling bezier curves:

DXF doesn’t preserve bezier curves well. Before exporting from Illustrator:

1. Select curved paths
2. Object → Path → Add Anchor Points (repeat as needed)
3. Object → Path → Simplify (check “Straight Lines”)

More anchor points before simplification means smoother curve approximation.

Method 4: SVG Export with Gerbolyze

Gerbolyze processes SVG files (which Illustrator exports) and renders them directly into Gerber format. It’s particularly good for artwork on existing PCB designs.

Workflow:

1. Export from Illustrator as SVG
2. Generate template from existing Gerbers: gerbolyze template –top template.svg gerber_dir
3. Open template in Illustrator, place your artwork
4. Merge artwork into Gerbers: gerbolyze paste –top template_edited.svg gerber_dir output_dir

Why this works well:

Gerbolyze handles the full SVG specification without rasterization. Vector data transfers losslessly to Gerber format. It’s tested with both KiCad and Altium Designer output.

Method 5: PNG Export Through KiCad Image Converter

For simpler graphics, exporting as high-resolution PNG and using KiCad’s bitmap converter provides an easy path.

Workflow:

1. Export from Illustrator as PNG (400+ DPI recommended)
2. Open KiCad Image Converter
3. Load PNG and configure settings
4. Export as KiCad footprint
5. Place footprint in PCB layout
6. Generate Gerber files from KiCad

Layer configuration in Image Converter:

Illustrator Element	KiCad Layer	Notes
Silkscreen graphics	F.SilkS or B.SilkS	Standard approach
Exposed copper areas	F.Cu or B.Cu	Requires editing layer in output file
Mask openings	F.Mask or B.Mask	Use “Negative” option

Preparing Adobe Illustrator Files for Conversion

Proper file preparation in Illustrator dramatically improves conversion success rates.

Convert All Text to Outlines

Gerber files don’t understand fonts. All text must be converted to paths.

1. Select text objects
2. Type → Create Outlines
3. Verify conversion by trying to edit the text

Flatten Transparency and Effects

Illustrator effects don’t translate to manufacturing:

• Gradients → Convert to solid colors or remove
• Transparency → Flatten (Object → Flatten Transparency)
• Blur/glow effects → Rasterize or remove
• Blend modes → Flatten

Organize Layers for PCB Mapping

Name your Illustrator layers to match PCB layer conventions:

Illustrator Layer Name	PCB Layer Purpose
TopCopper or F.Cu	Front copper
BottomCopper or B.Cu	Back copper
TopSilk or F.SilkS	Front silkscreen
BottomSilk or B.SilkS	Back silkscreen
TopMask or F.Mask	Front solder mask
BottomMask or B.Mask	Back solder mask
Outline or Edge.Cuts	Board boundary
Drill	Hole locations

Set Correct Document Units

1. File → Document Setup
2. Set units to millimeters or inches (not points or pixels)
3. Verify artboard size matches intended board dimensions

Handle Bezier Curves Appropriately

If your design includes curves and you’re using DXF export:

1. Select curved paths
2. Object → Path → Add Anchor Points (repeat 2-3 times)
3. Object → Path → Simplify
4. Check “Straight Lines”
5. Adjust curve precision slider for smoothness vs. file size

Step-by-Step Conversion Using DesignSpark PCB

Here’s a complete workflow using the free DesignSpark PCB software, which works well with Illustrator DXF exports.

Step 1: Prepare and Export from Illustrator

1. Finalize your design with proper layers
2. Convert all text to outlines
3. Flatten transparency and effects
4. File → Export → Export As → AutoCAD Interchange File (DXF)
5. Select R13/LT95 format, check “Maximum editability”

Step 2: Create New Project in DesignSpark

1. Launch DesignSpark PCB
2. File → New → PCB Design
3. Follow the PCB setup wizard
4. Set board dimensions matching your Illustrator artboard

Step 3: Import DXF File

1. File → Import
2. Select your exported DXF file
3. Position the imported graphics on the board
4. Assign elements to appropriate layers (copper, silkscreen, etc.)

Step 4: Generate Gerber Output

1. Output → Manufacturing Plots → Gerber/Excellon
2. Configure layer mapping
3. Set format to RS-274X
4. Generate output files
5. A .txt log file confirms successful generation

Step 5: Verify in Gerber Viewer

Always verify before manufacturing:

1. Open files in GerbV, KiCad GerbView, or online viewer
2. Check all layers are present
3. Verify dimensions and alignment
4. Confirm drill locations if applicable

Useful Resources and Tools for Illustrator to Gerber Conversion

Conversion Software

Tool	Platform	Cost	Best For
pdf2gerb	Cross-platform	Free	Direct PDF conversion from Illustrator
ACE 3000	Windows	Commercial	Professional PDF/PostScript conversion
FAB 3000	Windows	Commercial	Complex conversions with editing
Gerbolyze	Cross-platform	Free	SVG to Gerber with full spec support
reaConverter	Windows	Commercial	Batch AI to GBR conversion

PCB Design Software (for DXF import)

Software	Website	Cost
KiCad	kicad.org	Free
DesignSpark PCB	rs-online.com/designspark	Free
Eagle	autodesk.com/eagle	Free/Commercial
EasyEDA	easyeda.com	Free

Gerber Viewers for Verification

Viewer	Platform	Cost
GerbV	Cross-platform	Free
KiCad GerbView	Cross-platform	Free
ZofzPCB	Windows	Free
tracespace view	Online	Free

Documentation Links

• pdf2gerb: swannman.github.io/pdf2gerb
• ACE 3000: numericalinnovations.com/ace-2d-3d-translator
• Gerbolyze: github.com/jaseg/gerbolyze
• KiCad Image Converter: docs.kicad.org

Troubleshooting Common Illustrator to Gerber Issues

Problem: Curves Appear Jagged or Segmented

Cause: Bezier curves converted to too few line segments

Solution: Add more anchor points before simplifying curves, or use a tool like Gerbolyze that handles curves natively through SVG.

Problem: Elements Missing After Import

Cause: Unsupported Illustrator features (gradients, effects, clipping masks)

Solution: Flatten all effects and expand appearances (Object → Expand Appearance) before export.

Problem: Scale is Wrong in PCB Software

Cause: Unit mismatch between Illustrator and import settings

Solution:

• Set Illustrator document to mm or inches
• Match units in PCB software import dialog
• Use reference dimension to verify after import

Problem: DXF Has Duplicate Geometry

Cause: Adobe’s DXF export includes both polylines and hatches

Solution: Use PDF/PostScript export instead of DXF, or clean up duplicates in PCB software before generating Gerber.

Problem: Fills Don’t Convert Properly

Cause: Illustrator fills not interpreted as solid regions

Solution: Use ACE 3000 or FAB 3000 for proper fill handling, or convert fills to outlined shapes in Illustrator.

Frequently Asked Questions About Illustrator to Gerber Conversion

Can Adobe Illustrator Export Gerber Files Directly?

No, Adobe Illustrator cannot export Gerber files natively. Illustrator is designed for visual design, not PCB manufacturing. You need to export from Illustrator in an intermediate format (PDF, SVG, or DXF) and then use conversion software or PCB design tools to generate Gerber output. The pdf2gerb script offers the closest thing to “direct” conversion by reading PDF files exported from Illustrator.

What is the Best Method to Convert Illustrator to Gerber?

For most users, exporting as PDF and using ACE 3000 provides the most reliable results with professional support. For free solutions, pdf2gerb works well for properly structured files, while the DXF-to-PCB-software workflow offers flexibility. For artwork being added to existing PCB designs, Gerbolyze through SVG export provides excellent quality. Choose based on your budget, technical comfort level, and specific requirements.

How Do I Handle Drill Holes When Converting from Illustrator?

Drill information requires special handling since Illustrator doesn’t natively understand hole data. With pdf2gerb, represent drills as a solid black circle (copper pad) with a solid white circle on top (the hole), both on a dedicated Drill layer. For other methods, you may need to create the Excellon drill file separately by listing hole coordinates and diameters, or use PCB software to add drill data after importing the graphics.

Why Does My Converted Gerber Look Different from the Illustrator File?

Several factors cause visual differences. Bezier curves get approximated with straight line segments. Colors don’t exist in Gerber (everything is dark or clear). Gradients and transparency can’t be represented. Fine details below the manufacturer’s minimum feature size won’t reproduce. Always verify converted files in a Gerber viewer and compare against your original design before ordering boards.

Should I Use DXF or PDF Export from Illustrator for Gerber Conversion?

PDF is generally the better choice for Gerber conversion. Adobe’s DXF export creates files with duplicate geometry (polylines with hatches on top) that require cleanup. PDF preserves vector data cleanly and works directly with tools like pdf2gerb and ACE 3000. Use DXF only when your target software specifically requires it and be prepared to remove duplicate elements.

Best Practices for Illustrator to Gerber Workflow

After handling many Illustrator-to-Gerber projects, these practices consistently produce the best results:

Start with the end in mind. Know which conversion method you’ll use before designing. This influences how you structure layers and handle curves.

Keep a separate “production” version. Maintain your original Illustrator file with all effects intact for future editing. Create a flattened, converted version specifically for Gerber export.

Use proper layer organization from the start. Creating correctly named layers during design is much easier than reorganizing later.

Test early and often. Don’t wait until the design is “done” to attempt conversion. Run test exports early to catch problems while they’re easy to fix.

Verify at every step. Check the DXF or PDF in another application. Check the import in your PCB software. Check the Gerber output in a viewer. Catching errors early saves time and money.

Document your workflow. Once you find a process that works, write it down. Conversion settings, layer names, and export options are easy to forget between projects.

Conclusion

Converting Adobe Illustrator files to Gerber format isn’t a single-click operation, but it’s definitely achievable with the right approach. Whether you use pdf2gerb for direct PDF conversion, ACE 3000 for professional results, or route through PCB design software via DXF, the key is proper file preparation in Illustrator.

The most common mistakes, including using unsupported effects, skipping text-to-outline conversion, and ignoring curve handling, are all avoidable with proper preparation. Take time to structure your Illustrator file correctly, and the conversion process becomes much more reliable.

For designers who regularly create PCB artwork in Illustrator, investing in a commercial tool like ACE 3000 pays off quickly in time savings and reduced frustration. For occasional conversions, the free pdf2gerb script or the DXF workflow through free PCB software provides capable alternatives.

Whatever method you choose, always verify your Gerber output in a dedicated viewer before sending files to manufacturing. The few minutes spent checking saves days of waiting for incorrect boards.