How to Generate Gerber Files from PCBWeb Designer: Complete Manufacturing Guide

When Digi-Key and Aspen Labs launched PCBWeb Designer back in 2014, they created something unique in the EDA landscape: a completely free, full-featured PCB design tool with no limitations on board size, layer count, or component count. Having used this tool on several projects where the integrated Digi-Key component catalog proved invaluable, I can tell you that the Gerber export process is straightforward once you understand the workflow.

PCBWeb Designer generates standard Gerber output files that any PCB manufacturer will accept. The tool was designed specifically to streamline the path from design to fabrication, and exporting manufacturing files is integrated directly into the workflow alongside BOM management and component ordering.

Understanding PCBWeb Designer as a Free EDA Tool

Before diving into the Gerber generation process, it helps to understand what makes PCBWeb Designer different from other free PCB design tools. This context explains why the export workflow is designed the way it is and what features support the manufacturing process.

PCBWeb Designer was developed through a partnership between Aspen Labs (a joint-venture partner of Hearst Electronics Group) and Digi-Key Corporation. The software launched in October 2014 as a globally available, full-license application. Unlike many free EDA tools that impose restrictions, PCBWeb Designer has no artificial limitations on design complexity.

Key PCBWeb Designer Features

Feature	Description	Manufacturing Benefit
Multi-Sheet Schematics	Design complex circuits across multiple pages	Organized design documentation
Multi-Layer PCB Layout	Support for boards with multiple copper layers	Professional-grade board capability
Copper Pour	Automatic copper fill for ground planes	Improved signal integrity
Design Rule Check (DRC)	Validates layout against manufacturing rules	Prevents fabrication errors
Standard Gerber Output	RS-274X format export	Universal manufacturer compatibility
Integrated BOM Manager	Bill of materials with Digi-Key pricing	Streamlined procurement
Web Publishing	Share designs in browser format	Easy design collaboration
Built-in Board Ordering	Direct fabrication ordering	Simplified manufacturing workflow

PCBWeb Designer and Digi-Key Integration

One of PCBWeb Designer’s standout features is its exclusive link to Digi-Key’s component inventory. At launch, this included over four million searchable electronic components with approximately 300,000 ready-to-place parts with complete footprints.

Integration Feature	Capability
Component Search	Access Digi-Key’s full catalog
Ready-to-Place Parts	Pre-verified footprints and symbols
Real-Time Pricing	Current pricing information
BOM Export	Direct ordering from BOM
Availability Check	Stock status verification

What Gerber Files Does PCBWeb Designer Generate?

When you export manufacturing files from PCBWeb Designer, the software generates industry-standard RS-274X Extended Gerber files. This format is universally accepted by PCB manufacturers worldwide and includes embedded aperture definitions, making the files self-contained.

Complete Manufacturing File Package

File Type	Typical Extension	Purpose
Top Copper Layer	.GTL	Component side traces and pads
Bottom Copper Layer	.GBL	Solder side traces and pads
Inner Copper Layers	.G2, .G3, etc.	Internal signal and power layers
Top Solder Mask	.GTS	Mask openings on component side
Bottom Solder Mask	.GBS	Mask openings on solder side
Top Silkscreen	.GTO	Component reference designators
Bottom Silkscreen	.GBO	Bottom side markings
Board Outline	.GKO or .GML	Physical board dimensions
Drill File	.DRL or .XLN	Hole locations and sizes

Understanding the Gerber Format

PCBWeb Designer exports in RS-274X format, also known as Extended Gerber. This modern format includes several advantages over older Gerber formats:

RS-274X Feature	Benefit
Embedded Apertures	No separate aperture files needed
Self-Contained Files	Each file includes all definitions
Universal Support	Accepted by all modern manufacturers
Accurate Representation	Precise feature definitions

Preparing Your PCBWeb Designer Project for Export

Getting clean manufacturing output starts with proper design preparation. Before generating Gerber files, several steps ensure your design is ready for fabrication.

Running Design Rule Check (DRC)

PCBWeb Designer includes Design Rule Check functionality that validates your layout against manufacturing constraints. Always run DRC before exporting to catch potential issues.

The DRC checks for:

Rule Category	What It Validates
Trace Width	Minimum conductor dimensions
Trace Spacing	Clearance between copper objects
Drill Size	Minimum hole diameters
Annular Ring	Pad-to-hole relationships
Copper Clearance	Spacing to board edges
Short Circuits	Unintended connections

To run DRC in PCBWeb Designer, access the verification tools from the main menu. Review any errors or warnings and address them before proceeding with export. Unresolved DRC errors may result in manufacturing issues or rejected files.

Verifying Your Design Completeness

Before exporting, ensure your PCB design is complete:

All components from the schematic are placed on the board. All connections (ratsnest lines) have been routed as traces. Copper pours are properly defined and filled. The board outline is clearly defined on the appropriate layer. Silkscreen elements don’t overlap pads or vias. All design rule violations have been addressed.

Checking the Bill of Materials

PCBWeb Designer’s integrated BOM manager helps verify your component selections before manufacturing. Review the BOM to ensure all parts are available and correctly specified. This step prevents delays when ordering components for assembly.

Step-by-Step Guide to Generate Gerber Files from PCBWeb Designer

Now let’s walk through the actual process of generating Gerber files from PCBWeb Designer. The workflow is designed to be intuitive, with manufacturing outputs accessible from the main application menu.

Step 1: Complete Your PCB Layout

Ensure your design is finalized before generating manufacturing files. Switch to the PCB Layout view and verify that all traces are routed and no unconnected ratsnest lines remain. Check that your copper pours are properly filled and your board outline is clearly defined.

Step 2: Run Final Design Rule Check

Even if you’ve been running DRC throughout your design process, perform a final check before export. Access the DRC function from the Tools menu and run a complete check. Address any remaining errors before proceeding.

Step 3: Access the Export Function

To export Gerber files from PCBWeb Designer, navigate to the File menu. Look for the Export option, then select Gerber Files or Manufacturing Files depending on your software version. This opens the Gerber export configuration dialog.

Step 4: Configure Export Settings

In the export dialog, you’ll configure several important parameters:

Units Selection: Choose between inches or millimeters. Ensure this matches your design units and verify compatibility with your manufacturer’s requirements.

Format Settings: Select RS-274X (Extended Gerber) format for maximum compatibility. This format includes embedded aperture definitions.

Layer Selection: Choose which layers to include in the export. For a standard two-layer board, select top copper, bottom copper, top solder mask, bottom solder mask, top silkscreen, bottom silkscreen, and board outline.

Output Directory: Specify where the generated files should be saved. Creating a dedicated folder for manufacturing files helps keep your project organized.

Step 5: Configure Drill File Settings

Drill files require separate configuration. In the export dialog, locate the NC Drill or Excellon drill file settings. Configure the following:

Coordinate Format: Typically 2:4 or 2:5 format (integer:decimal digits). Match this to your Gerber settings for consistency.

Units: Same as your Gerber export units (inches or millimeters).

Zero Suppression: Select leading or trailing zero suppression based on manufacturer requirements.

Step 6: Generate the Files

After configuring all settings, click the Generate or Export button to create your manufacturing files. PCBWeb Designer will process your design and output all selected files to your specified directory.

Step 7: Verify Generated Files

After export, navigate to your output directory and verify all expected files are present. A complete manufacturing package for a two-layer board should include files for each copper layer, solder mask layers, silkscreen layers, board outline, and drill data.

Understanding PCBWeb Designer File Naming Conventions

PCBWeb Designer exports Gerber files following industry-standard naming conventions. Understanding these helps when uploading to manufacturers or troubleshooting issues.

Typical File Extensions

Extension	Layer Description
.GTL	Top Copper (Gerber Top Layer)
.GBL	Bottom Copper (Gerber Bottom Layer)
.GTS	Top Solder Mask
.GBS	Bottom Solder Mask
.GTO	Top Silkscreen (Overlay)
.GBO	Bottom Silkscreen (Overlay)
.GKO	Board Outline (Keep-Out)
.DRL	Drill File
.G2, .G3	Inner Layers (for multilayer boards)

Most manufacturers automatically recognize these standard extensions and assign layers correctly during their CAM process.

Exporting Additional Manufacturing Files

Beyond Gerber files, PCBWeb Designer supports exporting other files needed for complete manufacturing packages.

Bill of Materials (BOM) Export

The integrated BOM manager can export component lists for procurement. The export includes reference designators, component values, footprints, and Digi-Key part numbers when available.

To export the BOM, navigate to the BOM view and use the export function. Common export formats include CSV and Excel-compatible formats that can be uploaded to component distributors or assembly houses.

Pick and Place Files

For SMT assembly, you may need pick and place files (also called centroid or XY files). These contain the X/Y coordinates, rotation, and layer information for each component.

Check PCBWeb Designer’s export options for pick and place or centroid file export. The format typically includes columns for reference designator, X position, Y position, rotation angle, and layer (top or bottom).

Verifying Gerber Files Before Manufacturing

Never send Gerber files to a manufacturer without verification. PCBWeb Designer generates standard files that can be viewed in any Gerber viewer.

Recommended Gerber Viewers

Viewer	Platform	Cost	Features
Gerbv	Windows, Linux	Free	Open source, reliable
KiCad GerbView	Cross-platform	Free	Part of KiCad suite
Ucamco Reference Viewer	Online	Free	Official Gerber standard
ViewMate	Windows	Free	Industry standard
FlatCAM	Cross-platform	Free	CAM preparation capable
CAM350	Windows	Paid	Professional CAM tool

Verification Checklist

Check Item	What to Verify
Layer Count	All copper layers present
Board Outline	Closed shape, correct dimensions
Drill Alignment	Holes centered on pads
Solder Mask	Correct openings on all pads
Silkscreen	Readable, no pad overlap
Copper Pours	Properly filled areas
Trace Widths	Meet minimum specifications
Clearances	Proper spacing maintained

Common Issues to Check

When reviewing your PCBWeb Designer Gerber exports, pay particular attention to:

Drill-to-Pad Alignment: Verify drill holes are properly centered on pads. Misalignment can cause connection failures.

Solder Mask Openings: Ensure mask openings expose all pads that need soldering while covering traces and vias appropriately.

Board Outline Closure: The board outline must be a completely closed shape. Open outlines can cause manufacturing confusion.

Layer Registration: All layers should align properly. Use fiducial markers or alignment targets as reference points.

Working with PCB Manufacturers

Once you’ve verified your Gerber files, uploading to manufacturers is straightforward. PCBWeb Designer’s standard output format works with all major fabrication services.

Popular Manufacturers Accepting PCBWeb Gerber Files

Manufacturer	Upload Format	Notes
JLCPCB	ZIP archive	Auto-detects layers
PCBWay	ZIP archive	Gerber viewer included
OSH Park	ZIP archive	Drag-and-drop upload
Seeed Fusion	ZIP archive	Online preview
AllPCB	ZIP archive	DFM check available
Eurocircuits	ZIP archive	European fabrication

Preparing Files for Upload

Most manufacturers prefer receiving all Gerber and drill files in a single ZIP archive. To prepare your files:

Navigate to the folder containing your exported Gerber files. Select all manufacturing files (Gerber layers and drill file). Create a ZIP archive containing all selected files. Optionally include a readme file with any special instructions.

Using PCBWeb Designer’s Built-in Ordering

One of PCBWeb Designer’s unique features is built-in board ordering capability. This allows you to send your design directly to fabrication without manually downloading and uploading Gerber files.

Direct Fabrication Ordering

PCBWeb Designer includes integration with fabrication services that can accept designs directly from the software. This streamlines the ordering process by eliminating manual file handling.

To use this feature, look for the Order PCB or Send to Fabrication option in the application menu. Follow the prompts to configure board specifications (layers, thickness, surface finish) and submit your design.

Advantages of Integrated Ordering

Advantage	Benefit
Reduced Errors	Files transfer directly without manual handling
Faster Process	Skip download/upload steps
Integrated Pricing	See fabrication costs in the tool
Design Validation	Automatic DFM checks before ordering

Troubleshooting Common Export Issues

Based on user experiences and forum discussions, here are common issues encountered when exporting from PCBWeb Designer and their solutions.

Missing Layers in Export

If certain layers appear missing from your export, verify they contain actual content in your design. Empty layers may not generate output files. Also check that all required layers are selected in the export configuration.

DRC Errors Preventing Export

If design rule violations prevent export, run the DRC tool to identify and locate all errors. Common issues include trace spacing violations, copper clearance problems, or unconnected nets. Address each error before attempting export again.

Drill File Issues

Some users have reported drill file format issues with certain manufacturers. If your manufacturer reports problems with drill data, try adjusting the coordinate format settings (2:4 vs 2:5) or zero suppression options. Also verify that drill units match your Gerber units.

Copper Pour Problems

If copper pours don’t appear correctly in exported Gerbers, verify that pours are properly calculated in the PCB layout. Recalculate copper pours before exporting and verify they connect to the intended nets.

Useful Resources for PCBWeb Designer Users

Here are essential resources for working with PCBWeb Designer and generating manufacturing files:

Official Resources

Resource	Location	Description
PCBWeb Website	pcbweb.com	Main application site
Digi-Key Design Tools	digikey.com/resources/design-tools	EDA tool suite
EEWeb Community	eeweb.com	User community and support
PartSim	partsim.com	Related simulation tool
Scheme-It	digikey.com/schemeit	Related diagramming tool

Related Digi-Key Tools

PCBWeb Designer is part of a broader suite of EDA tools offered through Digi-Key:

Tool	Purpose	Integration
Scheme-It	Block diagrams and schematics	Concept design
PartSim	Circuit simulation	Design verification
Ultra Librarian	Component data	Symbols and footprints
BOM Manager	Parts list management	Procurement

Free Gerber Viewers

Viewer	Download Location
Gerbv	gerbv.geda-project.org
KiCad GerbView	kicad.org
Online Reference Viewer	gerber-viewer.ucamco.com
FlatCAM	flatcam.org
ViewMate	pentalogix.com/viewmate

PCB Manufacturers

Manufacturer	Website
JLCPCB	jlcpcb.com
PCBWay	pcbway.com
OSH Park	oshpark.com
Seeed Fusion	seeedstudio.com/fusion
AllPCB	allpcb.com

Frequently Asked Questions

What Gerber format does PCBWeb Designer export?

PCBWeb Designer exports RS-274X Extended Gerber format, which is the current industry standard accepted by virtually all PCB manufacturers worldwide. This format includes embedded aperture definitions, making the files self-contained and eliminating compatibility issues associated with older Gerber formats. Drill files are exported in Excellon format, which is also universally supported.

Is PCBWeb Designer really free with no limitations?

Yes, PCBWeb Designer was released as a full-license application with no limitations on number of parts, board size, or layer count. Unlike many free EDA tools that impose restrictions on design complexity, PCBWeb Designer provides professional-grade capabilities at no cost. The tool’s business model relies on integration with Digi-Key’s component sales rather than software licensing fees.

Can I use PCBWeb Gerber files with any manufacturer?

Yes, the Gerber files generated by PCBWeb Designer are industry-standard RS-274X format compatible with essentially any PCB manufacturer globally. Whether you’re ordering from budget prototype services like JLCPCB or premium fabricators, the standard Gerber format ensures compatibility. Some manufacturers also accept designs directly through PCBWeb’s integrated ordering feature.

How do I include inner layers for multilayer boards?

For multilayer PCB designs, PCBWeb Designer exports each inner copper layer as a separate Gerber file with sequential extensions (.G2, .G3, etc.). When configuring your export, ensure all inner layers are selected in the layer list. The files are automatically named according to layer position in the stack. Verify all inner layers are present in your export package before sending to manufacturing.

What should I do if my manufacturer reports file errors?

If your manufacturer reports issues with PCBWeb Gerber files, first verify the files in a third-party Gerber viewer like Gerbv or KiCad GerbView. Common issues include drill file format settings (try different coordinate formats), missing board outline, or layer naming conventions. Contact your manufacturer’s support for specific format requirements, and adjust your export settings accordingly. If problems persist, contact PCBWeb support or the EEWeb community for assistance.

Conclusion

Generating Gerber files from PCBWeb Designer is a straightforward process that produces industry-standard manufacturing outputs compatible with any PCB fabricator. The key steps involve completing your design with proper DRC validation, accessing the export function from the File menu, configuring Gerber and drill file settings appropriately, and verifying the generated files before sending to manufacturing.

What makes PCBWeb Designer particularly valuable is its integration with Digi-Key’s component ecosystem. You can design your board with verified component footprints, manage your BOM with real-time pricing, and generate manufacturing files all within the same environment. This integration eliminates the common disconnect between design tools and component procurement.

Remember to always verify your exported Gerber files in an independent viewer before sending them for fabrication. This simple verification step catches potential issues before they become expensive manufacturing mistakes. With PCBWeb Designer’s standard RS-274X format output and straightforward export process, you can move confidently from design to production knowing your files will be correctly interpreted by any PCB fabricator.

Whether you’re a hobbyist building your first custom board or an engineer working on production designs, PCBWeb Designer provides the manufacturing output capabilities you need without the licensing costs of traditional EDA software. The free access to professional-grade design and export tools, combined with seamless Digi-Key integration, makes it an excellent choice for projects where simplified component sourcing adds value to your workflow.