Gerber File Preparation: A PCB Production Checklist

1. Define what your Gerber package must communicate

Gerber is a format for exchanging PCB manufacturing data. Layer files describe images such as copper, solder mask and legend. Attributes defined by Ucamco can also identify layer functions and object types. Exporting these images, however, does not mean you have prepared every document needed to assemble a board.

Separate bare-board fabrication from component assembly when planning the handoff. Assembly also needs a bill of materials, placement information and useful orientation drawings. Confirm the accepted formats with the manufacturer before exporting. If the project uses another production data format, identify the authoritative package rather than sending two unchecked alternatives.

2. Freeze the design before generating outputs

Complete schematic-to-board updates, refill copper zones and run design rule checking before making the release. KiCad documentation explicitly warns that outdated zone fills can produce incorrect outputs. Record why any accepted exception is appropriate for this board.

Review mechanical details at the same time: finished dimensions, mounting holes, connector directions and enclosure clearances. A mounting hole moved by 1 mm may pass electrical checks while preventing the product from fitting its housing. Assign a revision to the approved design and generate the production files from that state. If a late change is necessary, regenerate the affected release together instead of replacing one file in an otherwise older archive.

3. Prepare layer images and drilling information together

A four-layer board needs a different layer set from a two-layer board. Confirm that every copper layer used in the design is included. Paste layers support stencil preparation and must not be confused with solder-mask layers. Export drills and slots in the format agreed with the fabricator; KiCad supports Excellon and Gerber X2 drilling output.

Use the following table as a review framework, adapting it to manufacturer requirements and board construction. Check the function and rendered contents of a file, not just its extension.

4. Open the exported files in an independent viewer

Approving the CAD view is different from checking the delivery. Start a clean Gerber viewer session and load the actual files extracted from the archive. Inspect layers separately, then overlay them with the drilling data. Two known mounting holes or opposite board corners make useful alignment references and can reveal an offset drill export quickly.

Measure the outline and resolve any uncertainty about mirrored views. Look closely at cutouts, mask openings, polarity marks, pin-one indicators and revision text. Check that text intended for the finished board remains readable in the correct viewing direction. A viewer opening the files successfully confirms that they can be interpreted visually; it does not approve electrical performance or establish that every feature is manufacturable.

5. Make the revision and production notes unambiguous

Folders called “final”, “final-new” and “old” force a recipient to guess which files matter. Deliver one approved package. A name such as “RV-CONTROL-R03_2026-10-18” can help, but the manufacturing note should also state the board code, revision, file list and technical contact.

Use the same note to communicate thickness, copper requirements, finish, quantity and panel expectations. If special tolerances or controlled impedance are needed, identify the relevant structures and discuss the verification requirement. Check the purchase form against the note before submission and resolve contradictory values before releasing the archive.

6. Rehearse the handoff using only the archive

Consider revision R03 of an 80 × 50 mm, four-layer control board. After exporting, the designer extracts the finished archive into another folder, counts all four copper layers and checks the drill alignment against the outline. The measured dimensions are compared with the production note. If assembly is included, the BOM revision is checked against the same release. This short rehearsal can expose a missing file or an earlier revision accidentally included in the archive.

Where possible, ask someone other than the exporter to perform the review. In a small team, pause briefly before reviewing only the extracted package. Keep the approved archive so later engineering questions can be tied to the exact delivery.

• Complete design checks and explain accepted warnings.
• Open copper, outline and drill data from the final archive.
• Match dimensions, layer order and special production requirements.
• Generate any BOM and assembly drawings from the same revision.
• Name the technical contact responsible for manufacturing questions.

Conclusion and next step

A useful Gerber delivery contains matching revisions and clear production instructions. Consistent naming, independent viewing and a short checklist help make the transfer from design to fabrication traceable and easier to review.