How to Generate Gerber Files from PCB Artist (Advanced Circuits): Complete Engineer’s Guide

As a PCB engineer who has spent countless hours troubleshooting manufacturing issues, I can tell you that getting your Gerber files right is the difference between a successful prototype and weeks of delays. PCB Artist, the free design software from Advanced Circuits (4PCB), simplifies the Gerber generation process considerably compared to other CAD tools, but there are still critical steps you need to follow to avoid common pitfalls.

This comprehensive guide walks you through everything from understanding what Gerber files actually contain to submitting your design for fabrication through Advanced Circuits’ streamlined workflow.

What Are Gerber Files and Why They Matter

Gerber files serve as the universal language between your PCB design and the fabrication house. Named after the company Gerber Scientific Instruments that developed the format in the 1960s, these files have become the de facto standard for PCB manufacturing data transfer.

Think of Gerber files as detailed blueprints that tell the manufacturer exactly where to etch copper, apply solder mask, print silkscreen, and drill holes. Each physical layer of your PCB gets its own Gerber file, and together they form a complete manufacturing package.

The Modern Gerber Format: RS-274X

Most manufacturers today, including Advanced Circuits, prefer the RS-274X format (also called Extended Gerber or X-Gerber). This format embeds aperture information directly within the file, eliminating the need for separate aperture wheel files that older formats required.

RS-274X offers several advantages for PCB engineers:

• Self-contained files with embedded aperture definitions
• Support for complex polygon fills and copper pours
• Better accuracy for fine-pitch components
• Reduced chance of misalignment between layers

PCB Artist Overview: Advanced Circuits’ Free Design Tool

PCB Artist is a fully-featured schematic capture and PCB layout software developed specifically for Advanced Circuits’ manufacturing ecosystem. The software integrates seamlessly with their ordering system, which means generating manufacturing files is remarkably straightforward compared to exporting from third-party tools.

Key PCB Artist Features for Manufacturing

Feature	Description	Benefit
Integrated DRC	Design Rule Checking built-in	Catches manufacturing issues before export
Direct Submit	Order directly from software	No separate file upload needed
FreeDFM Integration	Free design file checking	Validates files before fabrication
Auto-Router	Automated trace routing	Speeds up layout process
Component Library	500,000+ parts	Reduces custom footprint creation

Step-by-Step Process: Generating Gerber Files from PCB Artist

Step 1: Complete Your PCB Design

Before generating any manufacturing files, ensure your design is complete and error-free. This sounds obvious, but I’ve seen engineers rush to generate Gerbers only to find a missing trace or incorrectly placed component.

Pre-Export Checklist:

• All components placed and properly oriented
• All traces routed with no airwires remaining
• Power and ground planes defined correctly
• Board outline clearly defined on the proper layer
• Silkscreen text is legible and properly positioned
• Mounting holes placed with correct drill sizes

Step 2: Run Design Rule Check (DRC)

PCB Artist includes a comprehensive DRC tool that checks your design against manufacturing constraints. Access this through Tools > Design Rule Check from the menu bar.

The DRC will flag issues including:

• Trace widths below minimum specifications
• Clearances between copper features
• Drill hole sizes outside acceptable range
• Missing thermal reliefs on power planes
• Silkscreen overlapping pads

Pro Tip: Advanced Circuits’ standard capabilities include 6 mil minimum trace width and 6 mil minimum spacing for standard boards. Their Barebones service has slightly more relaxed rules, but always check their current specifications before finalizing your design.

Step 3: Access the Output Menu

In PCB Artist, manufacturing file generation is handled through the Output menu. Navigate to Output > Manufacturing Files to access the Gerber generation options.

PCB Artist simplifies this process significantly compared to other CAD tools. Rather than configuring each Gerber file individually, the software includes preset configurations optimized for Advanced Circuits’ manufacturing process.

Step 4: Configure Gerber Output Settings

When the Manufacturing Files dialog opens, you’ll see options for selecting which layers to include. For a standard two-layer board, ensure these files are generated:

Required Gerber Files for Two-Layer Board:

Layer Type	File Extension	Description
Top Copper	.GTL or .cmp	Top conductor layer
Bottom Copper	.GBL or .sol	Bottom conductor layer
Top Solder Mask	.GTS or .stc	Top solder mask openings
Bottom Solder Mask	.GBS or .sts	Bottom solder mask openings
Top Silkscreen	.GTO or .plc	Component reference designators
Bottom Silkscreen	.GBO or .pls	Bottom side markings (if used)
Board Outline	.GKO or .fab	Board dimensions and cutouts
NC Drill	.DRL or .drd	Drill hole locations and sizes

For four-layer or more complex boards, you’ll also need inner layer Gerbers designated as internal plane or signal layers.

Step 5: Generate NC Drill Files

The NC drill file (often in Excellon format) is equally critical as your Gerber files. This file tells the CNC drilling machine exactly where to place each hole and what size drill bit to use.

PCB Artist generates drill files automatically as part of the manufacturing output process. The drill file includes:

• XY coordinates for each hole
• Tool numbers corresponding to drill sizes
• Plated vs. non-plated hole designations

Common Drill File Issues to Avoid:

• Forgetting to differentiate plated through-holes from non-plated mounting holes
• Using drill sizes that don’t match the manufacturer’s available tool set
• Missing the drill file entirely from your submission package

Step 6: Submit Your Order

Here’s where PCB Artist really shines. Instead of manually packaging and uploading files, you can submit directly through the software.

Navigate to Output > Submit Order and PCB Artist will:

1. Perform a final DRC check
2. Generate all required manufacturing files
3. Package them appropriately
4. Connect to Advanced Circuits’ ordering system

You can enter promotion codes like the popular “33each” student/hobbyist deal directly in the submission dialog.

Understanding Advanced Circuits’ FreeDFM Tool

Even if you’re not ordering immediately, Advanced Circuits offers a free design file verification service called FreeDFM. This web-based tool analyzes your Gerber files and provides a detailed report identifying potential manufacturing issues.

What FreeDFM Checks

The FreeDFM analysis covers critical manufacturing parameters:

Check Category	What It Verifies
Copper Features	Trace widths, spacing, annular rings
Drill Data	Hole sizes, aspect ratios, missing drill file
Solder Mask	Swell settings, dam widths, coverage
Silkscreen	Minimum line widths, overlap with pads
Board Outline	Profile clarity, missing outline layer
Layer Alignment	Registration between layers

How to Use FreeDFM

1. Export your Gerber files from PCB Artist as a ZIP archive
2. Navigate to 4pcb.com and access the FreeDFM tool
3. Upload your ZIP file
4. Receive an email with a detailed PDF report
5. Address any flagged issues before ordering

Gerber File Naming Conventions

While PCB Artist handles naming automatically, understanding file extensions helps when troubleshooting or using external Gerber viewers.

Common Gerber File Extensions

Protel Style	Alternative	Layer
.GTL	.cmp	Top Copper
.GBL	.sol	Bottom Copper
.G2	.ly2	Inner Layer 2
.G3	.ly3	Inner Layer 3
.GTS	.stc	Top Solder Mask
.GBS	.sts	Bottom Solder Mask
.GTO	.plc	Top Silkscreen
.GBO	.pls	Bottom Silkscreen
.GKO	.fab	Board Outline
.DRL	.drd	NC Drill

Verifying Your Gerber Files Before Submission

Never submit Gerber files without visual verification. Even experienced engineers have been burned by assuming files were correct without checking.

Recommended Gerber Viewers

Several free tools let you inspect Gerber files before sending them to manufacturing:

Free Gerber Viewer Software:

• Gerbv (Open source, Linux/Windows)
• ViewMate (Windows, free version available)
• GC-Prevue (Web-based viewer)
• Ucamco Reference Gerber Viewer (Official reference viewer)
• KiCad Gerber Viewer (Part of KiCad suite)

What to Check in the Gerber Viewer

When examining your exported files:

1. Layer Alignment — Toggle layers on/off to verify registration
2. Copper Features — Confirm all traces are present and correct width
3. Drill Holes — Verify hole locations match pad centers
4. Solder Mask — Check for proper pad exposure
5. Silkscreen — Ensure text is readable and doesn’t overlap pads
6. Board Outline — Confirm profile is continuous and closed

Common Gerber Generation Errors and Solutions

Error 1: Missing Board Outline

The board outline defines where the manufacturer routes (cuts) your PCB from the panel. A missing or incomplete outline will cause a manufacturing hold.

Solution: In PCB Artist, ensure your board boundary is drawn on the Board Outline layer as a continuous, closed shape. Include any internal cutouts on this layer as well.

Error 2: Drill File Coordinate Mismatch

Sometimes drill coordinates use different units or precision than Gerber files, causing misaligned holes.

Solution: PCB Artist handles this automatically, but if using external tools, ensure both Gerber and drill files use the same coordinate system (typically 2:5 format, inches).

Error 3: Solder Mask Swell Issues

Solder mask openings that are too small can result in solder mask on pads, preventing good solder joints.

Solution: Most manufacturers add automatic solder mask swell (typically 3-5 mils larger than pads). Verify this setting matches your manufacturer’s recommendations.

Error 4: Silkscreen Over Pads

Silkscreen ink over exposed copper pads creates soldering problems.

Solution: Adjust silkscreen placement in PCB Artist to maintain clearance from all pad openings. Most manufacturers recommend at least 5 mil clearance.

Useful Resources for PCB Artist and Gerber Files

Official Documentation and Downloads

Resource	URL	Description
PCB Artist Download	4pcb.com/free-pcb-software	Free software download
PCB Artist Manual	Available after installation	Comprehensive user guide
FreeDFM Tool	4pcb.com/free-dfm	Free file verification
Advanced Circuits Support	4pcb.com/contact	Technical assistance

Learning Resources

Resource	Type	Best For
PCB Artist Tutorial PDF	Documentation	Step-by-step beginners
Advanced Circuits YouTube	Video Series	Visual learners
Gerber Format Specification	Technical Doc	Understanding the standard
PCBWay Gerber Tutorials	Blog Articles	Alternative perspectives

Gerber Viewer Downloads

Software	Platform	Link
Gerbv	Windows/Linux	gerbv.geda-project.org
ViewMate	Windows	pentalogix.com
KiCad	Cross-platform	kicad.org

PCB Artist vs. Exporting Gerbers from Other Tools

If you’re coming from Eagle, KiCad, or Altium, you’ll notice PCB Artist’s approach to Gerber generation is much more streamlined. Here’s a comparison:

Feature	PCB Artist	Eagle	KiCad
Direct Order Submission	Yes	No	No
Automatic File Packaging	Yes	Partial	No
Built-in DFM Check	Yes	No	No
CAM Configuration Required	Minimal	Extensive	Moderate
Learning Curve for Export	Low	Medium	Medium

The trade-off is that PCB Artist’s direct submission workflow is optimized specifically for Advanced Circuits. If you need to send files to other manufacturers, you’ll export Gerber files separately and lose some of the integration benefits.

Frequently Asked Questions

Can I use Gerber files from PCB Artist with other manufacturers?

Yes, you can export standard RS-274X Gerber files from PCB Artist for use with any manufacturer. Use the Export function rather than Submit Order, and you’ll receive industry-standard Gerber files that any fab house can process.

What happens if FreeDFM finds errors in my files?

FreeDFM provides a detailed report highlighting each issue. Common problems like insufficient clearances or missing layers are clearly identified. You can fix these issues in PCB Artist and re-run the check until you get a clean report. Advanced Circuits’ engineering team can also help resolve complex issues.

How do I generate Gerber files for a four-layer board in PCB Artist?

The process is identical to two-layer boards. PCB Artist automatically detects your layer stackup and generates the appropriate number of Gerber files. Ensure your internal layers are properly defined in the layer stack manager before generating output files.

Is PCB Artist really free with no limitations?

PCB Artist is genuinely free with full functionality. There are no board size limits, no layer restrictions, and no time limits. The only catch is that the most convenient submission workflow is designed for Advanced Circuits. However, you can still export standard files for use elsewhere.

Why won’t my drill file load in my Gerber viewer?

Drill files use a different format (Excellon) than Gerber files. Most modern Gerber viewers support both formats, but they may need to be loaded separately. Ensure your viewer is set to import Excellon format when loading drill files.

Best Practices for Multilayer Board Gerber Generation

When working with four-layer or higher layer count boards in PCB Artist, additional considerations come into play.

Inner Layer Considerations

Internal copper layers require special attention during Gerber export. PCB Artist handles most configurations automatically, but you should verify:

• Negative vs. Positive Planes — Power and ground planes are typically negative (copper everywhere except where removed), while signal layers are positive (copper only where defined)
• Thermal Reliefs — Through-hole pins connecting to planes need thermal reliefs for proper soldering
• Anti-Pad Sizing — Clearances around through-hole pins on non-connected planes must be adequate

Layer Stackup Documentation

For multilayer boards, include a stackup document or fabrication drawing showing:

• Layer order from top to bottom
• Copper weights for each layer (typically 1 oz standard)
• Dielectric material specifications
• Controlled impedance requirements if applicable

PCB Artist can generate a basic fabrication drawing, but complex boards may require additional documentation prepared separately.

Troubleshooting PCB Artist Gerber Export Issues

Software Won’t Generate Files

If PCB Artist refuses to generate manufacturing files, check these common causes:

1. Incomplete nets — Unrouted connections prevent export in some configurations
2. Design errors — Critical DRC violations may block file generation
3. License issues — Ensure PCB Artist is properly registered (free registration required)
4. Disk space — Insufficient storage can cause export failures

Files Won’t Upload to Advanced Circuits

When direct submission fails:

1. Check your internet connection
2. Verify your Advanced Circuits account is active
3. Try exporting files locally first, then upload manually through the website
4. Contact Advanced Circuits technical support if issues persist

Manufacturer Reports Missing Layers

If the fab house reports missing information despite generating all files:

1. Verify all files are included in the ZIP package
2. Check file naming matches manufacturer requirements
3. Ensure board outline is present and properly closed
4. Confirm drill file is in correct format (Excellon)

Advanced Circuits’ Manufacturing Capabilities

Understanding your manufacturer’s capabilities helps you design within achievable parameters. Advanced Circuits offers several service tiers:

Standard Specifications

Parameter	Capability
Minimum Trace Width	6 mil (0.006″)
Minimum Spacing	6 mil (0.006″)
Minimum Drill Size	10 mil (0.010″)
Maximum Board Thickness	125 mil (0.125″)
Copper Weight	1 oz to 2 oz standard
Solder Mask Colors	Green, Red, Blue, Black, White
Silkscreen Colors	White, Yellow, Black

Premium Capabilities

For more demanding designs, Advanced Circuits offers enhanced specifications including tighter tolerances, controlled impedance, blind/buried vias, and heavy copper options. Contact their engineering team for specific requirements.

Final Thoughts on Generating Gerber Files from PCB Artist

Getting Gerber files right the first time saves significant time and money. PCB Artist’s integrated approach removes much of the complexity typically associated with CAM processing, but understanding what’s happening behind the scenes helps you troubleshoot when things go wrong.

The key takeaways for reliable Gerber generation from PCB Artist:

1. Complete thorough DRC before exporting — catches most issues early
2. Use FreeDFM even if you think files are perfect — free insurance against manufacturing holds
3. Always verify files in a Gerber viewer — visual confirmation prevents expensive mistakes
4. Include all required layers — missing files cause delays
5. Understand your manufacturer’s capabilities — design within their specifications

The integration between PCB Artist and Advanced Circuits’ manufacturing systems represents one of the most streamlined paths from design to fabrication available to hobbyists and professionals alike. While other CAD tools offer more advanced features, the simplicity of PCB Artist’s Gerber generation workflow makes it an excellent choice for straightforward two and four-layer designs.

Whether you’re creating your first prototype or your hundredth production board, following these practices will help ensure your PCB arrives on time and works as designed. The few extra minutes spent verifying your Gerber files before submission will save you days of frustration and potentially hundreds of dollars in re-fabrication costs.