Why you should supply us with Gerber X2 files.

What are Gerber X2 Files?

Gerber X2 is an extended version of the standard Gerber file format, which is widely used in the PCB (Printed Circuit Board) manufacturing industry. It was introduced by Ucamco, the company that maintains the Gerber format, to address the limitations of the original Gerber format and provide a more efficient and streamlined PCB fabrication process.

Gerber X2 files contain all the necessary information for PCB fabrication, including the copper layers, solder mask, silkscreen, and drill data. The main advantage of using Gerber X2 files is that they include additional metadata, such as the layer structure, material stackup, and design intent information, which helps to reduce ambiguity and potential errors during the manufacturing process.

Benefits of Supplying Gerber X2 Files

1. Enhanced Communication and Clarity

One of the primary benefits of supplying Gerber X2 files is the improved communication between the PCB designer and the manufacturer. The embedded metadata in Gerber X2 files provides clear and unambiguous information about the PCB design, reducing the chances of misinterpretation or errors.

For example, Gerber X2 files include a clear definition of the layer structure, specifying the order and type of each layer in the PCB Stackup. This eliminates the need for additional documentation or clarification, as the manufacturer has all the necessary information within the Gerber X2 files themselves.

2. Streamlined Manufacturing Process

By supplying Gerber X2 files, you can help streamline the PCB manufacturing process. The enhanced metadata in Gerber X2 files allows for automated processing and reduces the need for manual intervention, which can be time-consuming and prone to errors.

For instance, Gerber X2 files include the material stackup information, specifying the thickness and type of each layer in the PCB. This allows the manufacturer to automatically set up their fabrication equipment, reducing the setup time and minimizing the risk of errors due to manual input.

3. Improved Design Validation

Gerber X2 files also enable better design validation before the manufacturing process begins. The embedded metadata allows for automated design rule checks (DRC) and other validation processes, which can identify potential issues early in the fabrication process.

For example, Gerber X2 files can include the minimum and maximum trace widths and clearances, as well as the via sizes and drill parameters. This information can be automatically checked against the manufacturer’s capabilities and design rules, ensuring that the PCB design is manufacturable and meets the required specifications.

4. Reduced Turnaround Time

By providing Gerber X2 files, you can help reduce the overall turnaround time for your PCB project. The enhanced metadata and automated processing enabled by Gerber X2 files minimize the need for back-and-forth communication between the designer and the manufacturer, which can be time-consuming and delay the project.

Moreover, the improved design validation and reduced setup time in the manufacturing process also contribute to a faster turnaround time. This means that you can receive your PCBs sooner and move forward with your project more quickly.

5. Cost Savings

Supplying Gerber X2 files can also lead to cost savings in your PCB project. The streamlined manufacturing process and reduced turnaround time enabled by Gerber X2 files can help lower the overall fabrication costs.

Additionally, the improved communication and reduced risk of errors can help avoid costly mistakes and rework, further contributing to cost savings in your project.

How to Generate Gerber X2 Files

Most modern PCB design software tools support the generation of Gerber X2 files. The exact process may vary depending on the specific software you are using, but the general steps are as follows:

1. Complete your PCB design, ensuring that all layers and components are properly defined and placed.
2. Set up the Gerber output settings in your PCB design software. Make sure to select the Gerber X2 format and specify the desired output directory.
3. Generate the Gerber X2 files by executing the Gerber output command in your software. This will create a set of files, typically one for each layer of the PCB, as well as the drill data and other necessary information.
4. Review the generated Gerber X2 files to ensure that they are complete and accurate. Most PCB design software tools include a Gerber viewer that allows you to visually inspect the files before sending them to the manufacturer.
5. Package the Gerber X2 files, along with any additional documentation or information, and send them to your chosen PCB manufacturer.

Common Mistakes to Avoid When Supplying Gerber X2 Files

While Gerber X2 files provide many benefits, there are still some common mistakes that can occur when generating and supplying these files. Here are a few things to keep in mind:

1. Incomplete or missing files: Make sure that you include all the necessary Gerber X2 files for your PCB design. This typically includes files for each copper layer, solder mask, silkscreen, and drill data. Missing files can delay the manufacturing process and lead to confusion.
2. Incorrect layer naming or order: Ensure that your Gerber X2 files follow a consistent and clear naming convention, and that the layer order is correctly specified in the metadata. Inconsistent or incorrect layer information can result in manufacturing errors.
3. Outdated or incompatible file formats: While Gerber X2 is the preferred format, some manufacturers may still accept older Gerber formats. However, using outdated or incompatible file formats can lead to problems in the manufacturing process. Always check with your manufacturer to confirm their file format requirements.
4. Inaccurate or missing metadata: The metadata in Gerber X2 files is crucial for clear communication and efficient manufacturing. Make sure that the metadata in your files is accurate and complete, including the layer structure, material stackup, and design intent information.
5. Not reviewing the files before sending: Always take the time to review your Gerber X2 files before sending them to the manufacturer. Use the Gerber viewer in your PCB design software to visually inspect the files and ensure that they are correct and complete.

FAQs

1. Can all PCB manufacturers accept Gerber X2 files?

Most modern PCB manufacturers can accept Gerber X2 files. However, it’s always a good idea to check with your chosen manufacturer to confirm their file format requirements and capabilities.

2. Are Gerber X2 files backward compatible with older Gerber formats?

Gerber X2 files are not backward compatible with older Gerber formats. However, most PCB design software tools can generate both Gerber X2 and legacy Gerber files, allowing you to provide the appropriate format for your manufacturer.

3. What if my PCB design software doesn’t support Gerber X2?

If your PCB design software does not support Gerber X2, you may need to use a separate Gerber file generation tool or upgrade to a newer version of your software that includes Gerber X2 support.

4. How do I ensure that my Gerber X2 files are correct and complete?

To ensure that your Gerber X2 files are correct and complete, follow these steps:

• Double-check your PCB design for errors or inconsistencies before generating the Gerber files.
• Ensure that you select the appropriate Gerber X2 output settings in your PCB design software.
• Visually inspect the generated Gerber X2 files using the Gerber viewer in your software.
• Confirm that all necessary files are included in the package you send to the manufacturer.
• Provide clear and accurate metadata in your Gerber X2 files, including layer structure, material stackup, and design intent information.

5. Can I include additional information or notes in my Gerber X2 files?

Yes, Gerber X2 files allow for the inclusion of additional information and notes through the use of attributes. These attributes can convey design intent, manufacturing requirements, or other relevant information to the manufacturer. However, it’s essential to ensure that your manufacturer can process and utilize these attributes effectively.

Conclusion

Supplying Gerber X2 files to your PCB manufacturer offers numerous benefits, including enhanced communication, streamlined manufacturing, improved design validation, reduced turnaround time, and potential cost savings. By providing clear, accurate, and complete Gerber X2 files, you can help ensure a smooth and efficient PCB fabrication process.

To maximize the advantages of Gerber X2 files, it’s crucial to follow best practices when generating and supplying these files. This includes using a compatible PCB design software, ensuring accurate and complete metadata, and thoroughly reviewing the files before sending them to the manufacturer.

By embracing the Gerber X2 format and working closely with your PCB manufacturer, you can optimize your PCB fabrication process and achieve better results in your projects.