How to Generate Gerber Files from Pulsonix: Complete PCB Engineer’s Guide

Having worked with numerous PCB design tools over the years, I’ve developed a real appreciation for Pulsonix’s approach to manufacturing output generation. The UK-based software strikes a solid balance between professional capabilities and usability that larger enterprise tools often sacrifice. When it comes to generating Gerber files from Pulsonix, the workflow is logical and well-integrated into the design environment.

This guide walks you through the complete process of creating manufacturing-ready Gerber files, NC drill data, and other fabrication outputs from Pulsonix, including the configuration details that make the difference between smooth manufacturing and costly delays.

Understanding Gerber Files in PCB Manufacturing

Gerber files have been the backbone of PCB manufacturing communication for decades. Originally developed by Gerber Scientific Instruments in the 1960s for vector photoplotters, the format has evolved into the RS-274X (Extended Gerber) standard that virtually every fabrication house accepts today.

Each Gerber file represents a single layer of your PCB as a 2D vector image. When a manufacturer receives your files, they load them into CAM software to prepare tooling for each fabrication step — copper etching, solder mask application, silkscreen printing, and board profiling.

The RS-274X Standard

Pulsonix outputs Gerber files in the RS-274X format, which embeds aperture definitions directly within each file. This self-contained approach eliminates the compatibility issues that plagued the older RS-274D format, which required separate aperture wheel files.

Key characteristics of RS-274X files include:

• Embedded aperture definitions (no external aperture files needed)
• Human-readable ASCII format for troubleshooting
• Support for complex polygons and thermal reliefs
• Universal compatibility with CAM systems worldwide

Pulsonix Overview: Professional PCB Design Software

Pulsonix is a Windows-based schematic capture and PCB layout application developed by WestDev in the UK. The software has been in continuous development since 1991 and serves over 9,000 users globally, including installations at major electronics companies.

Key Manufacturing Features in Pulsonix

Feature	Description	Manufacturing Benefit
CAM/Plot System	Comprehensive output dialog	Centralized manufacturing control
Plot Groups	Saved output configurations	Repeatable exports across revisions
Plot Wizard	Step-by-step guidance	Reduces configuration errors
ODB++ Export	Alternative to Gerber	Single-file manufacturing data
Technology Files	Pre-defined CAM settings	Consistent outputs across designs
Auto Generate	Automatic plot creation	Time savings for standard boards

Pre-Export Checklist: Preparing Your Design

Before opening the CAM/Plot dialog, take time to verify your design is truly ready for manufacturing output. Catching issues now saves significant time compared to discovering problems after fabrication begins.

Design Rule Check (DRC)

Run a comprehensive DRC to verify your design meets manufacturing constraints:

1. Navigate to Tools > Design Rule Check
2. Select all rule categories relevant to your manufacturer’s capabilities
3. Review and resolve any violations
4. Pay particular attention to clearance violations and unrouted connections

Verify Layer Stack Configuration

Ensure your layer definitions accurately represent your intended board construction:

• Confirm copper layer count matches your design intent
• Verify layer naming follows your manufacturer’s conventions
• Check that plane layers are correctly defined (positive vs. negative)

Board Outline Verification

Your board outline must be a continuous, closed shape:

• Check for gaps at corners or segment intersections
• Verify any internal cutouts are properly defined
• Confirm the outline appears on the correct documentation layer

Step-by-Step Guide: Generating Gerber Files from Pulsonix

Step 1: Access the CAM/Plot Dialog

Pulsonix centralizes all manufacturing output through the CAM/Plot option. Access it through:

Output Menu > CAM/Plot

The dialog presents a comprehensive interface for configuring all plot outputs, including Gerber files, drill data, and documentation drawings.

Step 2: Configure Plot Settings

The CAM/Plot dialog contains several key configuration areas:

Layer Selection: Select which design layers to include in your output. For a standard two-layer board, you’ll typically need:

Plot Type	Design Layer	Purpose
Top Copper	Elec 1 (Top)	Component-side traces
Bottom Copper	Elec 2 (Bottom)	Solder-side traces
Top Solder Mask	Solder Resist Top	Mask openings
Bottom Solder Mask	Solder Resist Bottom	Mask openings
Top Silkscreen	Silk Top	Component markings
Bottom Silkscreen	Silk Bottom	Solder-side markings
Board Outline	Assembly	Manufacturing boundary

Plot Scale and Rotation: Leave scale at 1:1 for manufacturing outputs. Rotation is typically unnecessary unless your manufacturer specifically requests it.

Machine Driver: Select the appropriate output format driver. For Gerber files, choose the Gerber driver from the available options.

Step 3: Configure Gerber-Specific Settings

Click the Setup button next to the Gerber driver selection to access detailed format options:

Gerber Setup Dialog Options:

Setting	Recommended Value	Notes
Format	RS-274X	Extended Gerber with embedded apertures
Units	Imperial or Metric	Match your design units
Integer Digits	2-3	Whole number precision
Decimal Digits	4-5	Fractional precision
Coordinate Type	Absolute	Industry standard
Zero Suppression	Leading	Most common format

Step 4: Access Change Format Dialog

For precise coordinate formatting control, use the Change Format option within the Gerber Setup:

Format Settings:

• Units: Choose Imperial (inches) or Metric (millimeters) based on your manufacturer’s preference
• Integer and Decimal: Together these define coordinate precision. Common configurations include 2.4 (imperial) or 3.3 (metric)
• Type: Absolute coordinates are standard; Incremental is rarely used

These settings are stored in the Windows Registry and apply to all subsequent plots until changed.

Step 5: Configure Aperture Settings

Pulsonix automatically generates apertures based on your design features, but you can access the aperture table through the Gerber Apertures option:

Aperture considerations:

• Review the aperture list to ensure all pad shapes and trace widths are represented
• Verify no custom apertures exceed your manufacturer’s capabilities
• Check that thermal relief patterns use appropriate aperture definitions

Step 6: Generate Individual Layer Plots

With settings configured, generate each required layer:

1. Select the layer combination from the layer list
2. Specify the output filename (use descriptive names like “TopCopper.gbr”)
3. Click Plot or Generate to create the file
4. Repeat for each required manufacturing layer

Step 7: Use Plot Groups for Efficiency

Pulsonix’s Plot Groups feature saves your output configurations for reuse:

1. Configure all required plots for your design
2. Save the configuration as a Plot Group
3. Load the Plot Group for future revisions of the same design
4. Modify only changed settings as needed

This feature significantly reduces setup time for repeat orders or design revisions.

Generating NC Drill Files in Pulsonix

Gerber files define copper features, but drill files specify hole locations and sizes. Manufacturing requires both file types.

Excellon Drill Format

Pulsonix supports the Excellon format for NC drill data, which is the industry standard accepted by virtually all fabricators.

Accessing Drill Output:

Navigate to Output > CAM/Plot and select the Excellon driver option. Configure the drill output settings:

Setting	Description	Recommendation
Units	Inch or Metric	Match Gerber settings
Format	Coordinate precision	Match Gerber format
Zero Suppression	Leading/Trailing	Match Gerber settings
Tool Table	Drill size list	Auto-generated from design

Drill File Considerations

Plated vs. Non-Plated Holes: Separate drill files for plated through-holes (PTH) and non-plated through-holes (NPTH) are best practice. Some manufacturers require this separation.

Drill Size Table: Pulsonix generates a drill size table showing all unique hole diameters in your design. Review this table to ensure sizes match your manufacturer’s standard drill inventory.

Slot and Routed Features: For slots or complex routed features, additional mill/rout files may be required. Pulsonix can generate these through the CAM/Plot system.

Using the Plot Wizard for Guided Output

For engineers new to Pulsonix or those who want step-by-step guidance, the Plot Wizard provides a structured approach to generating manufacturing outputs.

Accessing the Plot Wizard

From the CAM/Plot dialog, select the Plot Wizard option to launch the guided interface.

Wizard Steps

The Plot Wizard walks through:

1. Technology Selection: Choose or create appropriate technology file
2. Layer Configuration: Define which layers to output
3. Format Settings: Configure Gerber and drill parameters
4. Output Options: Specify file locations and naming
5. Generation: Create all configured outputs

The wizard is particularly useful for ensuring no required layers are accidentally omitted.

Auto Generate Feature for Standard Boards

Pulsonix includes an Auto Generate feature that automatically creates standard manufacturing outputs based on your layer stack and technology file settings.

When to Use Auto Generate

Auto Generate works well for:

• Standard two-layer or four-layer boards
• Designs using technology files with pre-configured CAM settings
• Quick prototype outputs where manual optimization isn’t critical

Auto Generate Limitations

Consider manual configuration when:

• Your design uses non-standard layer configurations
• Manufacturer-specific requirements differ from defaults
• Complex flexi-rigid or embedded component designs

Alternative Output: ODB++ Format

Beyond Gerber files, Pulsonix supports ODB++ export for manufacturers who accept this more comprehensive format.

ODB++ vs. Gerber Comparison

Aspect	Gerber Files	ODB++
File Count	Multiple (one per layer)	Single archive
Embedded Data	Images only	Images + netlist + components
Stack-up Info	External documentation	Included
Industry Support	Universal	Growing
File Size	Smaller per layer	Larger overall

Exporting ODB++ from Pulsonix

Access ODB++ export through the Output menu. The format includes layer images, drill data, component information, and netlist data in a single package.

Verifying Your Gerber Files

Never send Gerber files to manufacturing without verification. Visual inspection catches issues that design software might miss.

Using Pulsonix’s Built-in Viewer

Pulsonix includes a Gerber viewer for checking exported files. This allows you to verify outputs without leaving the design environment.

External Gerber Viewers

For independent verification, consider these free viewers:

Viewer	Platform	Notes
Gerbv	Windows/Linux	Open source, widely used
ViewMate	Windows	Professional quality
GC-Prevue	Windows	Free version available
Ucamco Reference Viewer	Web	Official Gerber format viewer

Verification Checklist

When reviewing Gerber files:

1. Toggle each layer individually to verify completeness
2. Check layer registration (alignment) by overlaying copper and mask layers
3. Verify drill holes align with pad centers
4. Confirm board outline is continuous and closed
5. Check silkscreen for legibility and pad clearance
6. Verify no features extend beyond the board outline

Common Pulsonix Gerber Export Issues

Issue 1: Coordinate Format Mismatch

Symptom: Drill holes appear offset from pads in viewer

Solution: Ensure Gerber and Excellon drill files use identical coordinate format settings (units, integer/decimal digits, zero suppression)

Issue 2: Missing Aperture Definitions

Symptom: Features appear as thin lines or incorrect shapes

Solution: Verify RS-274X format is selected (not RS-274D). Re-export with embedded apertures enabled.

Issue 3: Incomplete Board Outline

Symptom: Manufacturer reports missing or open board boundary

Solution: Check board outline layer for continuous, closed path. Verify outline exports on correct layer.

Issue 4: Text Font Issues

Symptom: Silkscreen text appears different than expected

Solution: Use Pulsonix’s standard fonts for Gerber output. Custom TrueType fonts may not translate correctly.

Issue 5: Thermal Relief Problems

Symptom: Plane connections appear solid or missing

Solution: Review thermal relief settings in pad styles. Verify power plane plots include correct thermal definitions.

Useful Resources for Pulsonix Users

Official Documentation

Resource	URL	Description
Pulsonix Main Site	pulsonix.com	Software and support
Online Documentation	pulsonix.com/documentation	Comprehensive help system
User Forum	pulsonix.com/forum	Community support
Download Center	pulsonix.com/downloads	Updates and resources

Gerber Verification Tools

Tool	Access	Cost
Gerbv	gerbv.sourceforge.net	Free
ViewMate	pentalogix.com	Free version
GC-Prevue	graphicode.com	Free
Reference Viewer	ucamco.com	Free

Manufacturer Resources

Always consult your specific PCB manufacturer’s documentation for:

• Preferred file formats and naming conventions
• Design rule requirements (minimum trace, spacing, hole sizes)
• Layer stack-up documentation requirements
• Special instructions for advanced technologies

Best Practices for Manufacturing File Management

Version Control

Implement systematic naming for Gerber exports:

ProjectName_Rev##_YYYYMMDD/├── ProjectName_TopCopper.gbr├── ProjectName_BottomCopper.gbr├── ProjectName_TopMask.gbr├── ProjectName_BottomMask.gbr├── ProjectName_TopSilk.gbr├── ProjectName_Outline.gbr├── ProjectName_Drill_PTH.drl├── ProjectName_Drill_NPTH.drl└── README.txt

Documentation Package

Include with your Gerber submission:

• All copper layer Gerbers
• Solder mask Gerbers (top and bottom)
• Silkscreen Gerbers (as needed)
• Board outline Gerber
• NC drill file(s)
• Fabrication notes or README
• Stack-up drawing for multilayer boards

Pre-Submission Verification

Before sending files:

1. View all layers in Gerber viewer
2. Verify drill alignment with copper
3. Confirm layer count matches order
4. Check file naming matches manufacturer conventions
5. Include all special instructions

Frequently Asked Questions

Can I generate Gerber files with the Pulsonix evaluation version?

Yes, the evaluation version includes full CAM/Plot functionality including Gerber and drill file generation. This allows you to test the complete workflow before purchasing a license.

Does Pulsonix support Gerber X2 format?

Pulsonix primarily outputs RS-274X format. While it can import files containing X2 commands, the software notes that X2-specific attributes (AperFunction, FileFunction) are detected but not fully processed. For most manufacturers, RS-274X remains sufficient.

How do I create Gerber files for a flexi-rigid design?

Pulsonix’s flexi-rigid support extends to manufacturing outputs. Use layer spans and bend region definitions in your design, then configure the CAM/Plot to output appropriate layers for each rigid and flexible section. Consult your manufacturer for their specific documentation requirements.

What’s the difference between Plot Groups and Technology Files?

Technology Files define design rules, styles, and default settings used during PCB creation. Plot Groups store specific CAM/Plot configurations for manufacturing output. Both work together — Technology Files can include default plot settings that Plot Groups can override for specific projects.

Can Pulsonix generate IPC-2581 format?

Pulsonix supports ODB++ as an alternative to Gerber. Check with your manufacturer whether they accept IPC-2581, and verify current Pulsonix version capabilities for this format.

Pulsonix vs. Other PCB Tools for Gerber Export

Having used multiple PCB design platforms, I can offer perspective on how Pulsonix compares for manufacturing output generation.

Gerber Export Comparison

Feature	Pulsonix	Altium Designer	KiCad	Eagle
Built-in Gerber Viewer	Yes	Yes	Yes	Limited
Plot Groups/Templates	Yes	OutJob files	Presets	CAM Jobs
Auto Generate	Yes	Partial	No	No
ODB++ Export	Yes	Yes	No	No
Technology File Support	Yes	Design Rules	Project files	DRU files
Learning Curve	Moderate	Steep	Moderate	Easy

Pulsonix Strengths for Manufacturing

Pulsonix excels in several areas for manufacturing output:

Integrated CAM/Plot System: Unlike tools that scatter output functions across multiple menus, Pulsonix consolidates everything in one comprehensive dialog. This centralized approach reduces the chance of missing required files.

Technology File Integration: The ability to embed CAM settings within Technology Files means new projects automatically inherit proven output configurations. This consistency is valuable for organizations producing multiple designs.

Plot Wizard Guidance: For engineers transitioning from other tools or new to PCB design, the Plot Wizard provides structured guidance that prevents common omissions.

Considerations for Tool Selection

Pulsonix pricing positions it between free tools like KiCad and premium solutions like Altium Designer. For organizations that need professional manufacturing output capabilities without enterprise-level costs, this represents good value.

The Windows-only platform may be a limitation for teams using Linux or macOS workstations, though Wine compatibility has been reported for some functions.

Advanced Topics: Multilayer and Specialty Board Outputs

Complex designs require additional attention during Gerber generation to ensure manufacturers receive complete, accurate data.

Multilayer Board Considerations

For boards with four or more layers, ensure your output includes:

Inner Layer Copper: Each inner signal or plane layer requires its own Gerber file. Pulsonix can output plane layers as positive (showing copper) or negative (showing clearances).

Blind and Buried Via Drill Files: Complex via structures may require separate drill files for different layer spans. Configure the Excellon output to properly differentiate these.

Layer Stack Documentation: Include a clear stack-up drawing or text file specifying layer order, copper weights, and dielectric materials.

Flexi-Rigid Design Outputs

Pulsonix provides true flexi-rigid support with manufacturing implications:

• Layer spans define which layers exist in rigid vs. flexible regions
• Bend regions require special documentation for the fabricator
• Stiffener locations should be clearly indicated on mechanical layers

Embedded Component Boards

For designs using embedded components within the PCB substrate, additional documentation beyond standard Gerber files is essential. Work closely with your manufacturer to determine their specific requirements.

Troubleshooting Advanced Gerber Issues

Issue: Copper Pour Rendering Problems

Symptom: Filled areas appear fragmented or incomplete in viewer

Solution: Pulsonix handles copper pours correctly according to industry reviews, but verify pour settings include proper thermal relief definitions. Regenerate pours before export if modifications were made late in the design cycle.

Issue: Panel Array Output

Symptom: Need to output panelized version for production quantities

Solution: Use Pulsonix’s panel editor to create the manufacturing panel, then generate Gerber files from the panel design rather than the individual board. This ensures step-and-repeat patterns and panel features are correctly captured.

Issue: Variant-Specific Outputs

Symptom: Design has multiple assembly variants requiring different manufacturing files

Solution: Pulsonix supports assembly variants. When generating outputs, ensure you’ve selected the correct variant or use Plot Groups to save variant-specific configurations.

Manufacturing File Submission Best Practices

Communicating with Your Fabricator

Before submitting files, establish clear communication:

1. Request Design Guidelines: Get your manufacturer’s capability document specifying minimum trace widths, spacing, hole sizes, and other constraints
2. Confirm File Format Preferences: While RS-274X is universal, some manufacturers prefer specific naming conventions or file organization
3. Discuss Special Requirements: HDI, controlled impedance, or specialty materials require additional documentation beyond standard Gerber files

Quality Assurance Before Submission

Implement a systematic review process:

• Compare Gerber output against original design in Pulsonix
• Verify all layers are present and correctly named
• Confirm drill file alignment with copper layers
• Check that board outline matches design intent
• Review silkscreen for manufacturing readability

Conclusion: Streamlining Your Pulsonix Manufacturing Workflow

Generating Gerber files from Pulsonix is a straightforward process once you understand the relationship between the CAM/Plot dialog, format settings, and output options. The software’s Plot Groups feature and Auto Generate capability can significantly reduce setup time for routine projects.

Key takeaways for reliable manufacturing output:

1. Use Technology Files to establish consistent CAM settings across projects
2. Run DRC before generating any manufacturing files
3. Match coordinate formats between Gerber and drill files exactly
4. Save Plot Groups for repeatable configurations
5. Verify all outputs in an independent Gerber viewer before submission

Pulsonix’s integrated approach to manufacturing output — combining Gerber, drill, ODB++, and documentation in a single dialog — provides efficiency that engineers appreciate. Whether you’re producing quick prototypes or preparing for production volumes, the CAM/Plot system delivers the flexibility needed for professional PCB manufacturing.