What are PCB Panelization Files? Complete Array Format Guide

If you’ve ever wondered why your PCB manufacturer asks for “panelization files” or charges extra for “array setup,” you’re not alone. After years of optimizing production layouts and troubleshooting assembly line issues, I’ve learned that understanding panelization files can mean the difference between a cost-effective production run and an expensive mistake.

This guide covers everything you need to know about PCB panelization files, from basic concepts to the technical specifications that will help you maximize board yield and minimize manufacturing costs.

What are PCB Panelization Files?

PCB panelization files are the design documents that define how multiple individual printed circuit boards are arranged on a larger manufacturing panel. These files contain all the information a fabricator needs to produce your boards in an array format, including board placement, spacing, separation methods, and the required tooling features.

When you submit your design to a manufacturer, you’re typically providing Gerber files for a single board. Panelization files take this further by specifying how many copies of your board (or multiple different boards) should be grouped together on a standard manufacturing panel. The result is an array—a collection of identical or mixed PCBs that travel through fabrication and assembly as a single unit before being separated into individual boards.

Why Panelization Files Matter for PCB Production

The electronics manufacturing process is designed around handling panels, not individual small boards. Pick-and-place machines, reflow ovens, and wave soldering equipment all work most efficiently with standardized panel sizes. Here’s what proper panelization files deliver:

Manufacturing Efficiency: Assembly equipment can populate dozens of boards simultaneously when they’re arranged in a panel. Without panelization, each small board would need individual handling, dramatically increasing production time.

Cost Reduction: More boards per panel means lower per-unit costs. The math is straightforward—if you can fit 20 boards on a panel instead of 15, you’ve just reduced your fabrication cost per board by roughly 25%.

Quality Control: Panels provide stable platforms during reflow soldering. Individual small boards can shift, twist, or even fall through conveyor gaps. Proper panelization maintains board rigidity throughout the assembly process.

Handling Protection: The rails and breakaway tabs in a panelized design protect delicate board edges and components from damage during manufacturing and shipping.

Types of PCB Panelization Files

Depending on your manufacturer and design software, you may encounter several file formats used to communicate panel specifications.

Standard Gerber-Based Panelization Files

The most common approach involves creating a new set of Gerber files that represent the entire panel rather than a single board. This panel Gerber package includes:

CAD Software Native Panel Files

Modern PCB design tools include built-in panelization features that generate panel-specific files:

Altium Designer: Uses the Embedded Board Array feature to create panel .PcbDoc files that can be exported to Gerber.

KiCad: The KiKit plugin or manual panel creation generates standard Gerber outputs for the complete array.

EAGLE: Panelization through ULP scripts or CAM processor configurations.

EasyEDA: Built-in panelization tools that output manufacturer-ready files.

Panel Drawing and Specification Files

Beyond Gerber data, comprehensive panelization files often include:

Panel Design Methods and Separation Techniques

The way boards connect within a panel directly impacts how they’ll be separated after assembly. Your panelization files must specify which method you’re using.

V-Groove (V-Score) Panelization

V-groove panelization involves cutting V-shaped channels partially through the panel material from both top and bottom surfaces. Each groove removes approximately one-third of the board thickness from each side, leaving a thin web of material (roughly one-third thickness) that holds the boards together.

V-Score Specifications for Panelization Files:

V-scoring works best for rectangular boards where score lines run straight across the entire panel. The boards separate cleanly with a slight bending motion or a scoring machine.

When to Use V-Scoring:

• Square or rectangular board shapes
• Components don’t hang over board edges
• Board thickness ≥1.0mm
• You need clean, smooth edges after separation

Tab Routing with Mouse Bites

When V-scoring isn’t feasible—typically due to irregular board shapes or edge-mounted components—tab routing with perforated breakaway tabs (mouse bites) provides an alternative.

Mouse bites are rows of small holes drilled into tabs that connect individual boards. After assembly, boards snap apart along these perforations, leaving small protrusions that may require sanding.

Mouse Bite Specifications:

When to Use Mouse Bites:

• Irregular or rounded board shapes
• Components near or overhanging board edges
• Mixed board designs in one panel
• Hand-separation is acceptable

Solid Tab Panelization

Some designs use solid tabs without perforations for maximum panel strength during manufacturing. These require specialized depaneling equipment:

• Router depaneling: CNC routing cuts boards from panel
• Laser cutting: Precise cuts without mechanical stress
• Blade tools: Hook-shaped cutters for manual separation

Solid tabs add cost and complexity but provide the strongest panel structure for heavy component loads or demanding assembly processes.

Essential Panel Features for Assembly

Your panelization files must include certain features to ensure compatibility with automated assembly equipment.

Tooling Holes

Tooling holes allow the panel to be precisely fixed in assembly fixtures and test equipment. Standard specifications:

Fiducial Marks

Fiducial marks are reference points that allow pick-and-place machines to precisely align component placement. They appear as exposed copper circles surrounded by solder mask clearance.

Panel Fiducial Requirements:

Rails and Borders

Rails are the border areas surrounding your board array. They provide handling area and house tooling holes and fiducials without interfering with the actual PCB designs.

Creating Panelization Files in Popular CAD Tools

Let me walk you through the basic process for the tools I use most frequently.

Panelization in Altium Designer

Altium’s Embedded Board Array feature handles most panelization tasks:

1. Create a new PCB document sized for your panel dimensions
2. Navigate to Place → Embedded Board Array/Panelize
3. Select your source .PcbDoc file
4. Define row and column count, spacing parameters
5. Add rails with tooling holes and fiducials
6. Define V-score lines on a mechanical layer or add mouse bite patterns
7. Export complete Gerber package including all layers

Panelization in KiCad

KiCad doesn’t have native panelization, but the KiKit plugin provides excellent functionality:

1. Install KiKit via pip: pip install kikit
2. Create a panel configuration file (JSON or CLI parameters)
3. Define board repetition, spacing, tabs/V-cuts
4. Generate panelized PCB file
5. Export Gerbers from the panel design

Alternatively, manual panelization involves copying and arranging board elements in a new PCB file.

Using Manufacturer Panelization Services

Most PCB manufacturers offer panelization as a service. You provide single-board Gerbers, and they create the panel. This approach works well but has considerations:

Advantages:

• No panel design work required
• Manufacturer optimizes for their processes
• Often included in assembly pricing

Disadvantages:

• Less control over panel layout
• May not optimize board count for your specific needs
• Panel design approval required before production

Read more PCB Files format:

What are .GBR and .PHO Files? Gerber File Extensions Guide

What are PCB Panelization Files? Complete Array Format Guide

What is .DSN File? Specctra Autorouter Format Explained

What is .kicad_pcb? KiCad PCB File Format Guide

What is .PcbDoc? Altium Designer PCB Format Explained

What is .PrjPcb? Altium Designer Project File Explained

What is .SchDoc? Altium Schematic File Explained

What is a .ASC File? PADS ASCII Format Explained

What is a .BRD File? Eagle PCB File Format Explained

What is a .DRC File? Design Rule Check Reports Explained

What is a .PCB File? Complete Protel/Altium PCB Format Guide

What is a .SES File? Complete Specctra Session File Guide for PCB Engineers

What is a BOM File? Bill of Materials Format for PCB Assembly

What is a CPL File? SMT Component Placement Guide

What is a Fabrication Drawing? PCB Fab Notes Explained

What is a Gerber Job File? Project Metadata Explained

What is a Netlist? PCB Connectivity Data Explained

What is a Pick and Place File? SMT Centroid Data Guide

What is a Stencil Gerber File? Complete Solder Paste Stencil Guide

What is an Aperture File? Gerber Tool Definition Guide

What is an Assembly Drawing? Complete PCB Assembly Documentation Guide

What is DXF in PCB Design? CAD Drawing Exchange Format Explained

What is Excellon? NC Drill File Format for PCB Manufacturing

What is GenCAD? Universal PCB Data Format Explained

What is Gerber RS-274X? The PCB Industry Standard Explained

What is Gerber X2? The Modern Gerber Format Guide

What is Gerber X3? Component Data in Gerber Files

What is HPGL? PCB Plotter File Format Guide

What is IGES? 3D PCB Model Format Explained

What is ODB++? Complete PCB Data Exchange Format Guide

What is PDF/A for PCB? Documentation Standards Guide

What is STEP File in PCB Design? 3D Model Exchange Guide

What is VRML in PCB? 3D Visualization Format Guide

Optimizing Panel Utilization

The number of boards you fit on a panel directly impacts cost. Here’s how to maximize utilization.

Standard Panel Sizes

Manufacturers work with standard panel sizes. Common options include:

Usable area is smaller due to border requirements (typically 12mm – 20mm around edges).

Board Rotation Considerations

Rotating boards 90° can sometimes fit more units per panel. However, consider:

• Grain direction: PCB laminate has a grain that affects dimensional stability. Mixed orientations may cause assembly issues.
• Assembly programming: Rotated boards require additional pick-and-place programming.
• Impedance variation: Critical RF traces may behave differently with grain orientation changes.

Calculating Board Yield

Use this approach to estimate boards per panel:

1. Start with panel usable area (total size minus borders)
2. Calculate board footprint including spacing and any rail requirements
3. Try both orientations
4. Account for partial board spaces that can’t be used

Many manufacturers provide online calculators, or you can use tools like KwickFit to optimize layouts before committing to a design.

Common Panelization Mistakes to Avoid

After reviewing hundreds of panel designs, these are the issues I see most frequently:

Insufficient Edge Clearance: Components too close to board edges get damaged during depaneling. Maintain at least 3mm clearance from any separation line.

Missing Fiducials: Without proper fiducials, placement machines can’t align accurately. Always include panel-level and board-level fiducials for fine-pitch components.

Wrong V-Score Depth: Specifying improper score depth leads to boards that won’t separate (too shallow) or break during handling (too deep). Let your manufacturer determine depth based on your board thickness.

Incompatible Separation Methods: Mixing V-scores and routed edges on the same board side creates manufacturing complications. Use one method consistently where possible.

Ignoring Component Overhang: Parts that extend beyond board edges need tab routing, not V-scoring. Check your 3D model before selecting separation method.

Useful Resources for PCB Panelization

Software Tools

Manufacturer Resources

Industry Standards

• IPC-7351: Generic Requirements for Surface Mount Design
• IPC-2221: Generic Standard on Printed Board Design
• IPC-A-610: Acceptability of Electronic Assemblies

Frequently Asked Questions About Panelization Files

What’s the difference between a panel and an array?

In PCB terminology, these terms are often used interchangeably, but there’s a subtle distinction. A “panel” typically refers to the full manufacturing substrate including borders and rails, while an “array” specifically describes the repeated arrangement of individual PCBs within that panel. When you create panelization files, you’re defining the complete panel, which contains your board array.

Can I put different PCB designs on the same panel?

Yes, this is called mixed panelization or multi-design panelization. However, all boards must share identical specifications: same layer count, same thickness, same surface finish, and same copper weight. If any parameter differs, the boards cannot be processed together. Mixed panels are common when you have several small designs that would otherwise waste panel space.

Should I create my own panelization files or let the manufacturer do it?

For prototypes and small production runs, letting the manufacturer handle panelization is usually the most practical choice. They’ll optimize for their equipment and processes. However, for high-volume production where per-unit cost is critical, creating your own panelization files gives you control over board count optimization and ensures the layout meets your specific assembly requirements.

How do I specify V-groove locations in my panelization files?

V-groove locations should be indicated on a dedicated mechanical layer in your Gerber output. Draw lines where you want the grooves to run—these must extend completely across the panel in straight lines. Include a fabrication note specifying the groove angle (typically 30° or 45°) and let the manufacturer determine appropriate depth based on your board thickness. Some manufacturers prefer a separate DXF file for scoring specifications.

What panel size should I request for my project?

Ask your manufacturer which panel sizes they run and what border spacing they require. Then calculate how many boards fit on each available panel size, accounting for spacing between boards (typically 2-3mm for routing, 0mm for V-scoring) and rail widths. Choose the panel size that yields the highest board count for your order quantity. For smaller orders, manufacturers often pool multiple customers’ boards on shared panels to reduce costs.

Final Thoughts on Panelization Files

Getting panelization right isn’t glamorous work, but it’s one of those fundamentals that separates efficient production from costly delays. The time you invest in understanding panel requirements, selecting appropriate separation methods, and creating proper panelization files pays off in lower manufacturing costs, smoother assembly runs, and fewer quality issues.

Start by consulting your manufacturer early in the design process. They can provide specific guidelines for their equipment and may offer panelization as a service. If you’re handling panelization yourself, use the specifications in this guide as a starting point, but always verify requirements with your fab house.

Remember that panelization isn’t just about fitting more boards on a panel—it’s about creating a manufacturable design that flows smoothly through fabrication, assembly, and test. Get the panel design right, and everything downstream becomes easier.