How to Convert Gerber to ODB++: Complete Guide for Intelligent PCB Data

If you’ve been in PCB manufacturing long enough, you’ve probably received that email from a fabricator asking for ODB++ instead of your standard Gerber package. More manufacturers are moving toward this intelligent data format because it streamlines their workflow and reduces errors. The challenge? Your design tool outputs Gerber, but your fab shop wants ODB++. This guide walks through everything you need to know about how to convert Gerber to ODB++, from understanding why this conversion matters to step-by-step processes using professional CAM tools.

Why Convert Gerber to ODB++?

Gerber files have served the PCB industry well for over 40 years, but they come with fundamental limitations. A Gerber file contains only graphical data—X-Y coordinates and aperture shapes. There’s no layer stackup definition, no drill information embedded, and no electrical connectivity data. This means fabricators must manually interpret your intent, increasing the risk of errors.

ODB++ addresses these limitations by packaging everything into a single, intelligent database structure. When a manufacturer requests ODB++, they’re looking for a complete data package that eliminates guesswork and accelerates their CAM process.

Aspect	Gerber RS-274X	ODB++
File structure	Multiple separate files	Single hierarchical database
Layer stackup	Not defined	Fully specified
Drill data	Separate Excellon files	Integrated
Netlist	Separate IPC-D-356 file	Embedded
Component data	Separate XY/BOM files	Included
Manufacturing notes	Separate documentation	Can be integrated
DFM analysis	Requires manual setup	Built-in support

Benefits of ODB++ for Manufacturing

Benefit	Description
Reduced setup time	Fabricators report 5x faster CAM processing
Lower error rate	Single source of truth eliminates file mismatches
Automated DFM	Built-in support for manufacturability analysis
Complete data package	Everything in one transferable unit
Assembly support	Component placement and BOM data included
Test data	Test point information for flying probe/ICT

Understanding the Conversion Challenge

Converting Gerber to ODB++ isn’t a simple format translation. Gerber files lack the intelligence that ODB++ requires. When you convert, you’re not just changing file formats—you’re enriching the data with information that didn’t exist in the original Gerber package.

What Gerber Contains

• Layer artwork (traces, pads, polygons)
• Aperture definitions
• Coordinate data
• Polarity information

What ODB++ Requires

ODB++ Element	Source
Layer images	From Gerber files
Layer stackup order	Must be defined manually
Layer types	Must be assigned (signal, plane, mask, silk)
Drill data	From Excellon files
Drill spans	Must be defined (through, blind, buried)
Board outline	From outline Gerber or must be created
Netlist (optional)	Extracted from copper layers or IPC file
Components (optional)	From XY centroid file or generated

The conversion process essentially reconstructs the design intent from the individual Gerber files, adding the structural and relational data that ODB++ requires.

Methods to Convert Gerber to ODB++

Several professional CAM tools can perform Gerber to ODB++ conversion. The process requires defining layer types, establishing the stackup, and optionally extracting or importing netlist data.

Method 1: Using FAB 3000 (Recommended)

FAB 3000 by Numerical Innovations is one of the most capable tools for Gerber to ODB++ conversion. It handles the complete workflow from import through intelligent ODB++ export.

Step-by-Step Process:

Step 1: Import Gerber and Drill Files

1. Launch FAB 3000
2. Go to File → Import → AutoLoad
3. Select the folder containing your Gerber and drill files
4. FAB 3000 will auto-detect file types
5. Verify layer type assignments are correct

Step 2: Define Layer Types

Each layer must be assigned a type for ODB++ to understand its function:

Layer Type	Description
Top	Top copper signal layer
Bottom	Bottom copper signal layer
Inner	Internal signal layers
Plane	Power or ground plane
Solder Mask Top	Top solder mask
Solder Mask Bottom	Bottom solder mask
Silk Top	Top silkscreen
Silk Bottom	Bottom silkscreen
Paste Top	Top solder paste
Paste Bottom	Bottom solder paste
Outline	Board outline/profile
Drill	Drill data (through, blind, buried)

Step 3: Create Board Outline (If Missing)

ODB++ requires a defined board boundary:

1. If outline layer exists, assign it as “Outline” type
2. If missing, go to Tools → Border → Create Border
3. Use automatic detection or draw manually

Step 4: Extract Netlist (Optional but Recommended)

Adding netlist data makes the ODB++ intelligent:

1. Go to Tools → Nets → Netlist Extraction
2. FAB 3000 traces connectivity across layers
3. Verify extracted nets appear correctly
4. If you have an IPC-D-356 netlist, import it for named nets

Step 5: Generate Components (Optional)

For assembly data inclusion:

1. If you have a centroid (XY) file, import it
2. Or use Tools → Components → Generate from Netlist
3. Review component outlines and positions

Step 6: Export to ODB++

1. Go to File → Export → ODB++
2. Configure export settings:
   1. Check “Optimize for Third-party software” if needed
   1. Verify layer stackup order
   1. Include/exclude optional data as required
3. Click Export and specify output location

Method 2: Using CAM350

CAM350 by DownStream Technologies is another professional-grade option for Gerber to ODB++ conversion.

Step-by-Step Process:

1. Create new CAM document
2. Import Gerber files via File → Import → AutoImport
3. Import drill files via File → Import → Drill Data
4. Assign layer types in the Layers Table
5. Define layer stackup order
6. Configure drill layer sets for blind/buried vias
7. Extract netlist via Tools → Netlist → Extract
8. Export via File → Export → ODB++

CAM350 ODB++ Export Options:

Option	Description
Include Netlist	Embed extracted net data
Include Components	Add component placement data
Step Name	Define step name for ODB++ structure
Units	Set output units (inch/mm)
Compression	Create compressed .tgz archive

Method 3: Using Altium CAMtastic

If you have Altium Designer, the integrated CAMtastic module can perform the conversion.

Step-by-Step Process:

1. Create new CAM document (File → New → CAM Document)
2. Import Gerber files (File → Import → Gerber)
3. Import drill files (File → Import → Drill)
4. Import IPC netlist if available
5. Assign layer types via Tables → Layer Type Detection
6. Define layer order via Tables → Layers Order
7. Configure drill pairs via Tables → Layers Sets
8. Extract netlist via Tools → Netlist → Extract
9. Export ODB++ via File → Export → ODB++

Method 4: Using Ucamco Reference Gerber Viewer

Ucamco (the Gerber format owner) offers tools that can work with Gerber X2/X3 files. While not a direct converter, properly attributed Gerber X2 files contain much of the intelligent data that ODB++ requires, making conversion more straightforward with compatible tools.

Configuring Layer Stackup for ODB++

The layer stackup is critical for ODB++ validity. This defines the physical arrangement of layers in the manufactured board.

Typical 4-Layer Stackup Example

Physical Order	Layer Name	Type
1	Top	Signal
2	Ground	Plane
3	Power	Plane
4	Bottom	Signal

Typical 6-Layer Stackup Example

Physical Order	Layer Name	Type
1	Top	Signal
2	Ground	Plane
3	Inner1	Signal
4	Inner2	Signal
5	Power	Plane
6	Bottom	Signal

Drill Layer Sets (Layer Pairs)

For boards with blind and buried vias, you must define which layers each drill file connects:

Drill File	Start Layer	End Layer	Via Type
drill_thru.drl	Top	Bottom	Through-hole
drill_blind_top.drl	Top	Layer 2	Blind
drill_blind_bot.drl	Layer 5	Bottom	Blind
drill_buried.drl	Layer 2	Layer 5	Buried

Adding Intelligence to Converted ODB++

Basic Gerber to ODB++ conversion creates a valid file, but you can add intelligence to make it more useful for manufacturing.

Netlist Extraction

Without a netlist, ODB++ is just organized artwork. With a netlist, manufacturers can:

• Perform electrical DFM checks
• Generate test programs automatically
• Verify connectivity during fabrication

Extraction Process:

1. Ensure layer stackup is correctly defined
2. Define drill pairs (which layers each drill file connects)
3. Run netlist extraction
4. Review extracted nets for completeness
5. Rename nets from IPC file if available

Component Data

Including component data enables:

• Pick-and-place file generation
• Assembly drawing creation
• Design for Assembly (DFA) analysis
• Bill of Materials integration

Component Generation Methods:

1. Import existing centroid (XY) file
2. Generate from netlist (identifies pin locations)
3. Manual component definition

Best Practices for Gerber to ODB++ Conversion

Before Starting

1. Verify all required Gerber files are present
2. Confirm drill files are complete and properly formatted
3. Gather any available IPC netlist files
4. Obtain centroid/XY files if assembly data is needed
5. Document the intended layer stackup

During Conversion

Practice	Why It Matters
Verify layer assignments	Wrong types cause fabrication errors
Check stackup order	Physical layer order affects manufacturing
Review drill pairs	Incorrect pairs create wrong via types
Validate board outline	Missing outline fails ODB++ requirements
Run DRC after extraction	Catches connectivity issues

After Conversion

1. Open the generated ODB++ in a viewer to verify
2. Check layer count matches original design
3. Verify drill data appears correctly
4. Confirm board outline is properly defined
5. Test netlist accuracy if extracted

Troubleshooting Common Issues

Problem: Layer Types Not Detected

Cause: File naming doesn’t match detection patterns

Solution:

• Manually assign layer types in the layers table
• Update detection templates with your naming convention
• Use standard naming conventions in future exports

Problem: Missing Board Outline

Cause: No outline layer or outline not closed

Solution:

• Create outline from copper layer extents
• Draw outline manually using board dimensions
• Import DXF outline if available
• Ensure outline is a closed polygon

Problem: Netlist Extraction Fails

Cause: Layer stackup or drill pairs incorrectly defined

Solution:

• Verify signal layers are marked correctly
• Check plane layers are assigned
• Confirm drill layer spans match design intent
• Ensure copper layers are properly aligned

Problem: Large ODB++ File Size

Cause: Complex copper pours or redundant data

Solution:

• Optimize polygon data before export
• Use compression option (.tgz)
• Simplify copper pour representations

Resources and Download Links

Commercial Software

Tool	Website	Trial Available
FAB 3000	numericalinnovations.com	Yes
CAM350	downstreamtech.com	Contact vendor
Altium Designer	altium.com	Yes
ViewMate Pro	pentalogix.com	Demo
Ucamco Integr8tor	ucamco.com	Contact vendor

ODB++ Resources

Resource	URL	Description
ODB++ Solutions Alliance	odbplusplus.com	Official specification
Siemens/Mentor	siemens.com/eda	Format owner
IPC Standards	ipc.org	Industry standards body

Related Format Documentation

Format	Source	Notes
ODB++ Specification	Siemens/Mentor	Format definition
Gerber RS-274X	Ucamco	Current Gerber standard
IPC-D-356	IPC	Netlist format
Excellon	Various	Drill file format

Frequently Asked Questions

Can I convert any Gerber file set to ODB++?

Yes, but the quality of the output depends on the completeness of your input. At minimum, you need copper layers, solder mask, and drill files. For intelligent ODB++, you also need an IPC netlist or the ability to extract one, and optionally component placement data. Simple two-layer boards convert easily; complex multilayer designs with blind/buried vias require careful drill pair configuration.

Will the converted ODB++ be identical to native ODB++ from my CAD tool?

Not exactly. Native ODB++ from tools like Altium or Allegro contains design-level intelligence that’s lost when exporting to Gerber. Converted ODB++ will contain the geometric data accurately, but some metadata, attributes, and design intent information may be missing or reconstructed. For most manufacturing purposes, converted ODB++ works perfectly; for advanced DFM analysis, native export is preferred when available.

Why does my manufacturer specifically request ODB++ instead of Gerber?

Manufacturers prefer ODB++ because it dramatically reduces their CAM processing time. Studies show that processing ODB++ takes about 1 hour compared to 5+ hours for equivalent Gerber packages on complex boards. The integrated data structure eliminates file matching errors, stackup interpretation issues, and drill registration problems that plague Gerber-based workflows.

Do I need to include netlist data in the ODB++?

For bare board fabrication, netlist data is optional but recommended. It enables the fabricator to run electrical DFM checks and generate test programs. For assembly services (PCBA), netlist data becomes more important as it ties components to their electrical functions. If your manufacturer doesn’t request it specifically, basic ODB++ without netlist will work for fabrication.

What’s the difference between ODB++ and IPC-2581?

Both are intelligent data formats designed to replace Gerber. ODB++ was developed by Valor (now Siemens) and uses a hierarchical folder structure. IPC-2581 is an open standard from the IPC consortium using XML format. Both contain similar information—layer data, stackup, netlist, components, and manufacturing notes. ODB++ has wider adoption currently, but IPC-2581 is gaining traction as a vendor-neutral alternative. Many CAM tools support both formats.

Conclusion

Converting Gerber to ODB++ bridges the gap between legacy design outputs and modern manufacturing requirements. While Gerber files will continue to be used for years to come, the industry trend toward intelligent data formats is clear. Understanding how to perform this conversion ensures you can meet any manufacturer’s requirements without re-exporting from your original design tool.

The key to successful conversion is treating it as a data enrichment process, not just a format change. You’re adding structure (layer stackup), relationships (drill pairs), and intelligence (netlist) that didn’t exist in the original Gerber package. With the right CAM tool and careful attention to layer assignments and stackup configuration, you can generate professional-quality ODB++ from any Gerber file set.

Whether you’re responding to a fab shop request, preparing files for a new manufacturer, or simply modernizing your data delivery workflow, the ability to convert Gerber to ODB++ is an increasingly valuable skill in PCB engineering.

For teams working with multiple manufacturers across different regions, having the flexibility to deliver both Gerber and ODB++ ensures you’re never held back by format requirements. Start with simple conversions on straightforward designs to build confidence, then tackle more complex multilayer boards as your understanding of the ODB++ structure deepens. The investment in learning this workflow pays dividends in smoother manufacturing handoffs and fewer costly errors during production.