PCB production file format Gerber and use IPC-2581 to compare who is the best format

Two dogs fight, play off.

Recently, we are all concerned about the best format battle between Ucamco Karel Tavernier and Mentor Graphics Julian Coates. Karel thinks that Gerber is the best format. The important thing is that the recently updated standard version of Gerber X2 is more mature than the one originally developed by Valor and later acquired by Mentor Graphics. It is worth mentioning that Julian Coates has fully supported the opening of ODB++ in order to cope with the monopoly, and the performance is excellent - the adoption of ODB++ in the industry is just a temporary move. Is this really due to potential monopoly support or is it because there is no other way? For more background information, please click here to read a report I recommend.

In the past few years, the latest file format transmitted to manufacturers by the PCB industry has always been a topic of interest. It is a bit obvious - the old RS-274x ("Gerber") is no longer suitable. At the same time, IPC2581 team members are working hard to develop new formats that will meet industry standards and address the issues that ODB++ and Gerber X2 face.

...but why do everyone love it?

Because of trouble

The old version of "Gerber" is a mature standard (which has been used for more than 30 years) and is approved by the public and old circuit printing manufacturers. However, Gerber has many limitations. RS-274X board designers have all but encountered the need to rename due to missing or misaligned holes, the manufacturer's incomprehension of the designer's gerber file extension, or, most severely, the appearance of the received board. Problems such as the wrong order led to production delays. So it's a good idea to sort the copper foil layers so that you can check after manufacturing - many designers do this for each board:

PCB production file format Gerber and comparison with IPC-2581 Who is the best format

But we must say that we have serious flaws in design communication with manufacturers. There are indeed some practices that can address the lack of information when passing data in the traditional format, but this should only be a matter of urgency.

List some common RS-274X defects:

Each layer of PCB information requires a separate physical file (eg, copper layer image, manufacturing record, assembly layer, etc.)

Unable to define board stack - must communicate the form, file name and text content with the manufacturer.

Does not contain drillhole information - The "NCDrill" file must be sent separately and often deviates from the drilling position in the gerber.

Does not contain any electrical connection information (network tables) and needs to send a separate netlist for electrical bare board testing - it is likely not to match the gerber file.

Does not contain any component layouts or BOM information - Individual pick-and-place files and procurement documents must be generated. This will lead to product delays, and it also poses a problem for co-operators who also undertake bare board manufacturing and assembly.

I PC-2581 and Gerber X2 Output Generator

IPC-2581 is the latest standard of the IPC (International Printed Circuits Industry Association). AlTIum is a member of the IPC-2581 Alliance, and AlTIum Designer 15 supports the manufacturer's data generation of the IPC-2581B specification. The IPC-2581 can generate stand-alone XML files that include all the information needed to manufacture and assemble printed circuit boards - whether bare boards or the entire production process, including: pick-and-place, and final testing. The IPC-2581 document includes:

The copper layer image of the printed circuit board is etched.

Slab stack information (including rigid and flexible parts).

Netlist for bare board and internal circuit testing.

BOM for component purchases and pick-and-place files for assembly.

Make and assemble remarks and their parameters.

Using this new standard means that you only need to send a single file to the manufacturer without the need for drilling files, printouts, PDF files, and manufacturing and assembly drawings - all the information needed to make a circuit board, all in the IPC-2581 XML database Already archived.

Gerber X2

This is an extended version of the Gerber RS-274X standard. The Gerber X2 can provide some of the same functionality as the IPC-2581, adding previously missing information to backward-compatible Gerber files such as layer stack definitions, pad and via attributes, and impedance Control wire. Netlists, drill holes and other outputs for testing can still be sent to manufacturers via their respective file formats. Gerber X2 offers an improved version of the manufacturing output format that is compatible with existing workflows, software and manufacturing equipment. Therefore, this is the preferred upgrade method that can be adopted by more conservative users.

Either way, it will encourage the industry to move forward, and which output method to choose depends largely on the manufacturer.

In Europe and North America, PCB manufacturers are urging designers to use the latest smart formats, because the "general old Gerber" is very expensive to use. Manufacturers with the latest CAM software can support IPC-2581, ODB++ and Gerber X2. All the manufacturers that I have communicated with have recognized this - Sierra, Hughes, Precision...

I would like to hear your thoughts - will you adopt a more conservative approach, insist on using Gerber, or will you adopt IPC-2581? If you adopt the latest format, what measures will you take to ensure the correctness of the circuit board together with the manufacturer?

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