How to Convert Gerber to PDF: Complete Guide for PCB Engineers

Every PCB engineer eventually faces this scenario: you need to share your board design with someone who doesn’t have CAM software. Maybe it’s a project manager reviewing the layout, a customer who wants to see what they’re paying for, or a colleague in mechanical engineering who needs to check clearances. Gerber files are great for manufacturing, but they’re not exactly universal. That’s where PDF comes in. This guide covers everything you need to know about how to convert Gerber to PDF, including the best tools, step-by-step methods, and tips for getting professional results.

Why Convert Gerber to PDF?

Before diving into the how, let’s address the why. Gerber files are the standard format for PCB fabrication data, containing precise information about copper layers, solder masks, silkscreen, and drill holes. But they require specialized CAM software to view, which not everyone has access to.

PDF (Portable Document Format) solves this problem elegantly. Anyone with a computer, tablet, or smartphone can open a PDF. The format preserves vector graphics quality, prints at any scale, and works across all operating systems.

Use Case	Why PDF Works Better
Design reviews	Team members can view without CAM software
Customer approval	Clients see exactly what they’re getting
Project documentation	Archives in universally readable format
Manufacturing notes	Add annotations and fab instructions
Quality control	Print and physically measure features
Presentations	Embed PCB images in reports and slides
DIY/hobbyist printing	Print for toner transfer or photoresist

Benefits of Converting Gerber to PDF

Converting your Gerber files to PDF format offers several practical advantages:

Benefit	Description
Universal accessibility	Opens on any device without special software
Vector quality preserved	Scales to any size without pixelation
Multi-layer support	Combine layers into single document
Annotation capability	Add notes, dimensions, and callouts
Print accuracy	Maintains 1:1 scale for physical prints
Easy sharing	Email or upload to any file sharing service
Archival format	Long-term storage without software dependencies

Understanding Gerber and PDF Formats

To convert Gerber to PDF effectively, it helps to understand what makes these formats similar and different.

Gerber Format Basics

Gerber files use vector commands to describe PCB features. The format is essentially a series of instructions telling a photoplotter where to draw lines, flash pads, and fill areas. Modern RS-274X (Extended Gerber) files include embedded aperture definitions, making them self-contained.

Gerber Characteristic	Description
File type	ASCII text with vector commands
Coordinates	X-Y positions in inches or mm
Apertures	Shape definitions (round, rectangle, etc.)
D-codes	Commands for draw, move, flash
Layer representation	One file per layer typically
Common extensions	.gbr, .ger, .gtl, .gbl, .gto, .gbo

PDF Format Basics

PDF also uses vector graphics, which is why Gerber-to-PDF conversion works so well. The coordinate systems and drawing commands are conceptually similar. Both formats describe where to draw lines and shapes, just with different syntax.

PDF Characteristic	Description
File type	Binary with embedded vector/raster data
Coordinates	Points relative to page origin
Graphics	Lines, curves, fills, text
Layers	Supports multiple layers in single file
Scalability	Infinite zoom without quality loss
Compression	Reduces file size while preserving quality

Methods to Convert Gerber to PDF

There are several approaches to converting Gerber files to PDF, ranging from free command-line tools to professional CAM software. The best method depends on your needs: single conversions, batch processing, or integration with existing workflows.

Method 1: Using GerbView (Commercial)

GerbView by Software Companions is one of the most popular tools for Gerber-to-PDF conversion. It supports both RS-274D and RS-274X formats and offers extensive conversion options.

Step-by-Step Process:

1. Download and install GerbView (30-day free trial available)
2. Launch GerbView and go to File → Import → Gerber
3. Select the Gerber files you want to convert
4. All layers load into the workspace with individual visibility controls
5. Go to File → Export → PDF
6. Configure output settings:
   1. Single multi-layered PDF (layers as PDF layers)
   1. Multi-page PDF (one layer per page)
   1. Individual PDF files (one per layer)
7. Set page size, scale, and color options
8. Click Export to generate the PDF

GerbView Feature	Description
Multi-layer PDF	Preserves layer structure in PDF
Custom colors	Assign colors to each layer
Transparency	Control layer opacity
Scale options	1:1, fit to page, or custom
Bookmarks	PDF bookmarks for each layer
Batch processing	Convert multiple jobs at once

Method 2: Using Gerber2PDF (Free/Open Source)

Gerber2PDF is a free command-line tool that converts Gerber files to PDF while preserving vector quality. It’s perfect for automation and scripting.

Installation:

Download from SourceForge or GitHub. The tool runs on Windows, Linux, and macOS.

Basic Usage:

Gerber2PDF -o output.pdf file1.gbr file2.gbr file3.gbr

Common Options:

Option	Function
-o filename	Specify output PDF filename
-combine	Place all layers on single page
-colour R,G,B	Set layer color (0-255 values)
-background R,G,B	Set background color
-transparent	Enable transparency
-nocombine	Each layer on separate page
-strokes2fills	Convert strokes to filled polygons
-CMYK	Use CMYK color space

Example for Multi-Page PDF:

Gerber2PDF -o board_layers.pdf Top.gtl Bottom.gbl TopMask.gts BotMask.gbs

Example for Combined View with Colors:

Gerber2PDF -o combined.pdf -combine -colour 255,0,0 Top.gtl -colour 0,255,0 Bottom.gbl

Method 3: Using ViewMate (Free Viewer with Print)

ViewMate by PentaLogix is a free Gerber viewer that has been an industry standard for over 35 years. While it doesn’t directly export PDF, you can print to PDF using any PDF printer driver.

Step-by-Step Process:

1. Download ViewMate from pentalogix.com (free registration required)
2. Install and launch the application
3. Go to File → Import → Gerber
4. Select your Gerber files
5. Arrange layer visibility and colors as desired
6. Go to File → Print
7. Select a PDF printer (Microsoft Print to PDF, Adobe PDF, etc.)
8. Configure print settings for scale and page size
9. Print to create the PDF

ViewMate Capability	Notes
Import formats	RS-274D, RS-274X, Gerber X2
Drill files	Also imports Excellon format
Measurements	Built-in measurement tools
Layer colors	Customizable per layer
Print output	Through system print dialog
Cost	Free for viewing and printing

Method 4: Using HQDFM (Free with PDF Export)

HQDFM (High Quality DFM) is a free tool from NextPCB that includes Gerber viewing and PDF export functionality, along with design rule checking.

Step-by-Step Process:

1. Download HQDFM from NextPCB website
2. Install and launch the application
3. Import your Gerber files
4. Click File in the upper left corner
5. Select Export PDF
6. Configure page settings and layer selection
7. Save the PDF file

This tool is particularly useful because it combines PDF export with DFM analysis, letting you catch manufacturing issues while preparing documentation.

Method 5: Using CAM350 (Professional)

CAM350 by DownStream Technologies is professional CAM software used in PCB manufacturing. If you have access to it, PDF export is straightforward.

Step-by-Step Process:

1. Import Gerber files into CAM350
2. Go to File → Print or File → Export → PDF
3. Select PDF as the output format
4. Choose layers to include
5. Configure page size and scale
6. Save the PDF

Method 6: Using Gerbv (Free/Open Source)

Gerbv is an open-source Gerber viewer available for Windows, Linux, and macOS. It supports PDF export through its File menu.

Step-by-Step Process:

1. Download Gerbv from gerbv.github.io
2. Open your Gerber files (File → Open Layer(s))
3. Adjust layer colors and visibility
4. Go to File → Export → PDF
5. Configure export settings
6. Save the PDF

Gerbv Feature	Description
Platform	Windows, Linux, macOS
License	Free and open source (GPL)
Gerber support	RS-274X only
Drill support	Excellon format
Export formats	PDF, PNG, SVG, PS

Method 7: Online Conversion Tools

Several online services offer Gerber-to-PDF conversion without installing software. These are convenient for quick one-off conversions but may not be suitable for confidential designs.

Online Service	Features
PCBWay Online Viewer	Free viewer with print capability
JLCPCB Gerber Viewer	Free online preview
GerbLook	Free online rendering
pdfFiller	Direct Gerber-to-PDF conversion

Caution: When using online converters, consider that your design data is uploaded to third-party servers. For sensitive or proprietary designs, use offline tools instead.

Creating Multi-Layer and Multi-Page PDFs

Most PCB projects include multiple Gerber files representing different layers. When converting to PDF, you have several options for organizing these layers.

Multi-Layer PDF (Recommended for Design Review)

A multi-layer PDF places all Gerber layers into a single PDF file where each PCB layer becomes a PDF layer. Viewers can toggle layer visibility, making this ideal for design reviews.

Benefits:

• Single file contains entire design
• Toggle layers on/off in PDF viewer
• See layer interactions
• Reduce file count

How to Create in GerbView:

1. Load all Gerber layers
2. Export to PDF
3. Select “Create layered PDF” option
4. Each Gerber layer becomes a named PDF layer

Multi-Page PDF (Good for Documentation)

A multi-page PDF places each Gerber layer on its own page within a single PDF file. This works well for documentation packages and printing individual layers.

Benefits:

• Easy navigation with page thumbnails
• Print individual pages/layers
• Clear separation between layers
• Works in all PDF viewers

How to Create: Most conversion tools offer a “one layer per page” option. In Gerber2PDF, omit the -combine flag.

Individual PDF Files (For Maximum Flexibility)

Creating separate PDF files for each layer provides maximum flexibility but results in more files to manage.

When to Use:

• Sending specific layers to different recipients
• Including in automated documentation systems
• Creating layer-specific inspection documents

Best Practices for Gerber to PDF Conversion

After years of converting Gerber files to PDF for various purposes, I’ve developed some practices that consistently produce good results.

Choose the Right Scale

Purpose	Recommended Scale
Screen review	Fit to page
1:1 printing	100% (actual size)
Documentation	Fit with margins
Large boards	Multiple pages (poster mode)

Use Appropriate Colors

Different colors help distinguish layers when viewing combined layouts.

Layer Type	Suggested Color
Top copper	Red
Bottom copper	Blue
Top solder mask	Yellow (transparent)
Bottom solder mask	Green (transparent)
Top silkscreen	White
Bottom silkscreen	Cyan
Drill holes	Black
Board outline	Black

Include Drill Data

Don’t forget to include drill files when creating PDF documentation. Drill holes are critical for verifying via placement and component mounting holes.

Add Annotations When Needed

Many PDF creation tools allow adding text annotations, dimensions, and callouts. Use these for:

• Revision notes
• Special manufacturing instructions
• Dimension callouts for mechanical interfaces
• Reference designator highlights

Troubleshooting Common Conversion Issues

Problem: Layers Appear at Wrong Scale

Cause: Coordinate unit mismatch between Gerber and conversion software

Solution: Check that the conversion tool is set to the correct units (inches or millimeters). Most modern Gerber files specify units in the header, but older files may need manual configuration.

Problem: Missing or Incorrect Apertures

Cause: RS-274D files without embedded apertures or corrupted aperture data

Solution: Ensure you’re using RS-274X files. If working with RS-274D, load the aperture table before conversion.

Problem: PDF Shows Only Outlines (No Fills)

Cause: Some converters handle polygon fills differently

Solution: Try the -strokes2fills option in Gerber2PDF, or check fill settings in your conversion software.

Problem: File Size Too Large

Cause: High-resolution rasterization or unoptimized output

Solution:

• Use vector output instead of raster
• Reduce DPI for raster elements
• Enable PDF compression
• Simplify complex polygons if possible

Problem: Colors Don’t Match Expectations

Cause: RGB vs CMYK color space issues or transparency settings

Solution: Configure color space in export settings. Use CMYK for print-intended documents and RGB for screen viewing.

Resources and Download Links

Free Software

Tool	Download Link	Platform
Gerber2PDF	sourceforge.net/projects/gerber2pdf	Windows, Linux, macOS
Gerbv	gerbv.github.io	Windows, Linux, macOS
ViewMate	pentalogix.com	Windows
HQDFM	nextpcb.com	Windows
KiCad GerbView	kicad.org	Windows, Linux, macOS

Commercial Software (Free Trials Available)

Tool	Website	Trial Period
GerbView	gerbview.com	30 days
ViewMate Pro	pentalogix.com	Demo available
CAM350	downstreamtech.com	Contact vendor

Online Viewers

Service	URL
Ucamco Reference Viewer	ucamco.com
PCBWay Viewer	pcbway.com
JLCPCB Viewer	jlcpcb.com
GerbLook	gerblook.org

Frequently Asked Questions

Can I convert PDF back to Gerber?

Yes, but with limitations. Tools like GerbView can convert PDF to Gerber, but only if the PDF contains vector graphics (not scanned images). The conversion may not perfectly recreate the original Gerber data, especially for complex designs. It’s always better to keep your original Gerber files.

Does converting Gerber to PDF lose any data?

For visualization purposes, no. The PDF will accurately represent what the Gerber file describes. However, PDF is an image format, not a manufacturing format. You cannot use a PDF to manufacture a PCB, and manufacturing-specific metadata (like aperture definitions and D-codes) isn’t preserved in a usable form.

What’s the best free tool to convert Gerber to PDF?

For most users, Gerber2PDF offers the best combination of quality, features, and ease of use. It preserves vector graphics, supports multi-layer and multi-page output, and runs on all major operating systems. ViewMate is excellent if you prefer a graphical interface and can use print-to-PDF.

Can I print the PDF at actual size for toner transfer?

Yes, this is a common use case for hobbyists. Set the print scale to 100% (actual size) and disable any “fit to page” options in both the conversion software and your PDF viewer’s print dialog. Always verify dimensions with a ruler before committing to the etching process.

How do I include drill holes in my Gerber to PDF conversion?

Drill files (Excellon format) must be converted separately or loaded alongside Gerber files. Most conversion tools support both formats. In GerbView and ViewMate, import drill files using the separate Drill import function, then include them in your PDF export. In Gerber2PDF, you may need to convert drill files to Gerber format first using the Drill2Gerber companion tool.

Conclusion

Converting Gerber to PDF bridges the gap between specialized manufacturing data and universal document sharing. Whether you’re preparing design reviews, creating documentation, or printing layers for DIY fabrication, the tools and techniques in this guide will help you get professional results.

For occasional conversions, free tools like Gerber2PDF, Gerbv, or ViewMate work excellently. For regular use or batch processing, consider GerbView or integrate Gerber2PDF into automated workflows using scripts.

The key is choosing the right output format for your purpose: multi-layer PDFs for interactive review, multi-page PDFs for documentation, and properly scaled single-page PDFs for printing. With the right approach, your PDF output will accurately represent your PCB design and serve its intended purpose effectively.