How to Generate Gerber Files from DesignSpark V7.0.0: A Complete Engineering Guide

Gerber files remain the universal standard for communicating PCB designs to manufacturers worldwide. When working with DesignSpark PCB V7.0.0, engineers must understand the precise workflow for generating manufacturing-ready output files. This comprehensive guide walks you through the complete process of generating Gerber files from DesignSpark V7.0.0, ensuring your designs translate accurately from schematic to physical board.

Understanding Gerber File Requirements

Before diving into the export process, it’s essential to understand what constitutes a complete Gerber file package. Manufacturers require several distinct files to fabricate your PCB accurately. These typically include copper layer files for each signal layer, solder mask files for both top and bottom surfaces, silkscreen layers containing component designators and reference markings, paste mask files for SMT assembly, and drill files specifying hole locations and dimensions.

DesignSpark V7.0.0 supports the RS-274X extended Gerber format, which embeds aperture definitions directly within the file structure. This eliminates the need for separate aperture files and reduces the risk of mismatched configurations during manufacturing. Understanding this format specification ensures compatibility with virtually all PCB fabrication facilities globally.

Accessing the Manufacturing Plots Interface

The Gerber generation process in DesignSpark V7.0.0 begins through the Manufacturing Plots interface. Navigate to Output in the main menu bar, then select Manufacturing Plots from the dropdown options. This action opens the plot configuration window where all export parameters are defined.

The Manufacturing Plots dialog presents a comprehensive interface for managing output files. Engineers familiar with previous DesignSpark versions will notice refinements in V7.0.0 that streamline the workflow while maintaining backward compatibility with established production processes.

Utilizing the Auto-Gen Plots Feature

DesignSpark V7.0.0 includes an intelligent Auto-Gen Plots function that significantly accelerates the setup process. Upon clicking Auto-Gen Plots, the software automatically analyzes your design and creates appropriate plot definitions for each layer in your stackup. This feature proves particularly valuable for multi-layer designs where manual configuration would otherwise require substantial time investment.

The automatic generation algorithm examines your layer configuration and creates corresponding Gerber outputs for copper layers, mask layers, and silkscreen layers. While this automation handles the majority of requirements, engineers should always verify the generated plot list against their specific manufacturing specifications.

Configuring Gerber Output Parameters

After the initial plot generation, select the Gerber option to access format-specific settings. This step is critical for ensuring your output files meet industry standards and manufacturer requirements.

Within the Gerber configuration dialog, click the Options button to reveal advanced settings. The primary consideration here involves selecting the appropriate Gerber format specification. DesignSpark V7.0.0 supports multiple format variants, but RS-274X represents the current industry standard and should be selected for all modern fabrication workflows.

The RS-274X format, often called Extended Gerber, offers several advantages over legacy formats. It includes embedded aperture definitions, supports polygon fills, and provides clear layer identification within the file header. These characteristics eliminate common sources of manufacturing errors associated with older format specifications.

Additional parameters within the Options menu allow engineers to customize output precision, coordinate format, and units. For most applications, the default settings provide adequate precision. However, designs featuring ultra-fine pitch components or high-density interconnects may benefit from increased decimal precision in coordinate specifications.

Generating NC Drill Files

Accurate drill data is equally important as copper layer information for successful PCB fabrication. DesignSpark V7.0.0 provides dedicated NC Drill output capabilities accessible through the Manufacturing Plots interface.

Click the NC Drill option to configure drill file generation. The resulting dialog presents options for drill file format, units, and coordinate specifications. Most manufacturers accept Excellon format drill files, which DesignSpark generates by default.

Verify that the drill file configuration matches your Gerber coordinate system to ensure proper registration between layers. Mismatched units or coordinate origins between Gerber and drill files represent a common source of manufacturing defects that can render boards unusable.

The NC Drill configuration also allows specification of plated versus non-plated hole differentiation. Designs incorporating both through-hole components and mounting holes should generate separate drill files for each category, enabling manufacturers to apply appropriate plating processes.

Selecting Output Plots

With configuration complete, the next step involves selecting which plots to include in your output package. The Manufacturing Plots interface displays a comprehensive list of available outputs with checkbox controls for each item.

For comprehensive manufacturing packages, engineers should select all relevant plots. This approach ensures manufacturers receive complete information while avoiding the overhead of manual selection for each individual layer. Redundant files within the package cause no issues during fabrication, whereas missing files invariably result in delays and clarification requests.

Review the selected plots to confirm inclusion of all copper layers matching your design stackup, both solder mask layers, silkscreen layers for component identification, paste mask layers if assembly services are required, and board outline definition.

Adding the Board Outline Layer

One frequently overlooked requirement involves the board outline layer. DesignSpark V7.0.0 may not automatically generate this critical file depending on how your design was constructed. Without clear outline definition, manufacturers cannot accurately determine board dimensions and routing paths.

If your plot list lacks a board outline entry, manual addition is necessary. Create a new plot definition and configure it to output the mechanical layer containing your board boundary. Ensure this layer exports as a separate Gerber file clearly identified as the board outline or mechanical layer.

The board outline should consist of a continuous closed path defining the PCB perimeter. Internal cutouts, slots, and complex edge features should also appear on this layer. Manufacturers use this information for CNC routing operations that separate individual boards from production panels.

Executing the Plot Generation

With all configurations verified, initiate the Gerber generation process by clicking the Run button. DesignSpark V7.0.0 processes each selected plot sequentially, generating individual files according to specified parameters.

Monitor the generation process for any warning or error messages. Common issues include missing aperture definitions for custom pad shapes, unconnected copper pours, or geometry extending beyond board boundaries. Address any reported issues before proceeding to file packaging.

The output files appear in your specified destination directory upon successful completion. DesignSpark creates individual files for each plot, typically with extensions indicating layer function such as .GTL for top copper, .GBL for bottom copper, and .DRL for drill data.

Packaging Files for Manufacturer Submission

The final step involves packaging all generated files into a single compressed archive. Create a ZIP or RAR file containing all Gerber outputs, drill files, and any supplementary documentation required by your manufacturer.

Before submission, verify your package using a standalone Gerber viewer application. This verification step catches potential issues before files reach the manufacturer, avoiding costly delays and re-submissions. Many free Gerber viewers are available online, and most PCB manufacturers also offer web-based verification tools.

Include a readme file or fabrication notes specifying layer stackup, material requirements, surface finish preferences, and any special processing instructions. Clear communication of requirements prevents manufacturing ambiguities and ensures your boards meet design specifications.

Conclusion

Generating Gerber files from DesignSpark V7.0.0 follows a logical workflow that, once mastered, becomes second nature for experienced engineers. The combination of automated plot generation and comprehensive configuration options provides flexibility for both simple two-layer designs and complex multi-layer stackups. By following the procedures outlined in this guide and verifying outputs before submission, engineers can confidently transition designs from DesignSpark to physical PCBs with minimal risk of manufacturing issues.