How to Generate Gerber Files from DipTrace: A Complete Engineering Guide

Generating Gerber files from DipTrace is an essential skill for PCB engineers preparing designs for fabrication. DipTrace offers a streamlined workflow that simplifies the export process compared to other EDA tools like Altium Designer or Eagle. This guide provides a detailed walkthrough of the entire Gerber generation process, including configuration options, file formats, and best practices for error-free PCB manufacturing.

Understanding Gerber Files and Their Role in PCB Fabrication

Before diving into the export process, engineers must understand what Gerber files represent. Gerber files serve as the industry-standard format for communicating PCB design data to manufacturers. Each file contains vector-based information describing individual layers of your circuit board, including copper traces, solder masks, silkscreen, and board outlines.

DipTrace exports Gerber files in the RS-274X format, also known as Extended Gerber. This format embeds aperture information directly within the file, eliminating the need for separate aperture definition files required by the older RS-274D standard. Modern PCB fabrication houses universally accept RS-274X files, making DipTrace’s default export settings compatible with virtually any manufacturer.

Additionally, DipTrace supports Gerber X2 export, which includes enhanced metadata about layer functions and board characteristics. However, for maximum compatibility with fabrication services, the standard RS-274X format remains the recommended choice unless your manufacturer specifically requests Gerber X2.

Preparing Your DipTrace Design for Gerber Export

Proper preparation ensures clean Gerber output and prevents manufacturing delays. Before initiating the export process, engineers should complete several verification steps within DipTrace’s PCB layout editor.

First, run a Design Rule Check (DRC) to identify clearance violations, unconnected nets, or trace width issues. DipTrace’s built-in DRC tool catches potential problems that could cause fabrication failures or functional defects in the finished board. Address all errors and warnings before proceeding with Gerber generation.

Second, verify your board outline layer contains a properly closed polygon defining the PCB boundary. Manufacturers rely on this outline to determine routing paths and panel placement. An incomplete or missing board outline will trigger rejection from most fabrication services.

Third, check text elements throughout your design. DipTrace allows both TrueType and vector fonts on silkscreen layers. For reliable Gerber export, convert all text to vector format by selecting Edit → Edit Selection → Text, right-clicking the selection, and choosing Font Type → Vector. This conversion prevents rendering issues that occasionally occur with TrueType fonts during Gerber generation.

Step-by-Step Gerber File Export Process

The Gerber export workflow in DipTrace consists of two primary operations: exporting layer Gerbers and generating NC drill files. Both file types are mandatory for complete PCB fabrication data.

Exporting Layer Gerber Files

Navigate to the export function through File → Export → Gerber in the PCB layout editor’s main menu. DipTrace displays the Gerber RS-274X export dialog, presenting a list of available layers for export.

The default configuration includes all standard layers required for typical two-layer and multilayer PCB fabrication. These layers encompass top and bottom copper, top and bottom solder mask, top and bottom silkscreen, and board outline. For multilayer designs, DipTrace automatically lists all internal copper layers as well.

Configure the export parameters according to your manufacturer’s specifications. Key settings include coordinate format and unit selection. DipTrace offers both imperial (inches) and metric (millimeters) options. In inch mode, the software uses a 4:4 format providing 0.1 mil resolution. Metric mode uses a 5:3 format with 0.001mm resolution, offering slightly finer precision.

Click the Export All button to generate all selected layer files simultaneously. DipTrace prompts for a save location and filename for each layer. Alternatively, enable the option to output all files into a single ZIP archive, significantly streamlining the process and ensuring all necessary files remain together.

Generating NC Drill Files

Drill file generation requires a separate export operation. Navigate to File → Export → N/C Drill after completing the Gerber layer export. DipTrace opens the NC drill export dialog displaying tool information and drill statistics.

Click Auto Tools to allow DipTrace to automatically configure drill sizes based on your design’s via and pad specifications. The software analyzes all through-holes, vias, and mounting holes, creating an optimized tool list for CNC drilling operations.

Export the drill file using Excellon format, the industry standard that all PCB manufacturers accept. DipTrace generates a single file containing all drill coordinates and tool definitions. Save this file to the same location as your Gerber files to maintain organized fabrication data packages.

For designs requiring blind or buried vias, export separate drill files for each drill span. DipTrace handles this automatically when multiple drill configurations exist in your design.

Understanding DipTrace Gerber File Extensions

DipTrace assigns the .gbr extension to all exported Gerber files by default. The software names files according to layer names, resulting in outputs like TopCopper.gbr, BottomMask.gbr, and BoardOutline.gbr. This naming convention provides clarity but may require adjustment for certain fabrication services.

Some manufacturers expect specific file extensions corresponding to layer types. Common alternative extensions include .GTL for top copper, .GBL for bottom copper, .GTS for top solder mask, .GBS for bottom solder mask, .GTO for top silkscreen, and .GBO for bottom silkscreen. DipTrace allows custom naming during export if your manufacturer requires these conventions.

Drill files typically receive the .drl or .txt extension. Verify your manufacturer’s requirements and rename files accordingly before submission.

Verifying Gerber Output Quality

Never submit Gerber files to fabrication without independent verification. Import your exported files into a standalone Gerber viewer to confirm accuracy and completeness. Several free tools exist for this purpose, including online viewers offered by PCB manufacturers and desktop applications like GerbView or ViewMate.

During verification, examine each layer individually and check layer-to-layer alignment. Confirm that drill holes align correctly with pads on copper layers. Verify solder mask openings expose the intended pad areas without encroaching on traces. Ensure silkscreen text appears readable and does not overlap solder mask openings or exposed copper.

Pay particular attention to the board outline layer. The boundary should form a continuous closed path without gaps or overlapping segments. Verify any internal cutouts or slots appear correctly in both the outline Gerber and corresponding drill operations.

Common Export Issues and Solutions

Engineers occasionally encounter problems during DipTrace Gerber generation. Understanding common issues accelerates troubleshooting and prevents project delays.

Font rendering failures represent the most frequent export problem. If text appears corrupted or missing in exported Gerbers, convert all text to vector format as described in the preparation section. This solution resolves nearly all text-related export issues.

Missing drill files cause fabrication rejections more often than any other omission. Remember that DipTrace requires separate export operations for Gerbers and NC drills. Develop a checklist ensuring both exports complete before packaging files for submission.

Layer misalignment in the finished board often traces back to inconsistent origin settings during export. Maintain the Use Design Origin option enabled throughout all export operations to ensure consistent coordinate references across all files.

Optimizing Your DipTrace Workflow

DipTrace stores Gerber export settings in a configuration file named gsettings.dat. On Windows systems, this file resides in C:\ProgramData\DipTrace\Data_Unicode. Backing up this file preserves your customized export configurations across software updates or system migrations.

For projects requiring frequent Gerber regeneration during development, consider establishing standard export presets aligned with your preferred manufacturer’s requirements. This approach eliminates repetitive configuration and reduces the risk of inconsistent exports between design iterations.

Conclusion

Generating Gerber files from DipTrace follows a straightforward process that engineers can master quickly. The software’s intuitive export dialogs and sensible default configurations reduce complexity while maintaining compatibility with industry standards. By following the procedures outlined in this guide—preparing designs properly, exporting both Gerber layers and NC drill files, and verifying output quality—engineers ensure their PCB designs translate accurately into manufactured hardware. The combination of RS-274X Gerber format and Excellon drill files provides fabrication houses with all information necessary to produce circuit boards matching your original design intent.