How to Convert Eagle to Gerber

Introduction to Eagle and Gerber Files

Eagle (Easily Applicable Graphical Layout Editor) is a popular electronic design automation (EDA) software used for designing printed circuit boards (PCBs). It allows users to create schematic diagrams and PCB layouts for their electronic projects. Once the PCB Design is complete, it needs to be converted into a format that can be understood by PCB manufacturers. This is where Gerber files come into play.

Gerber files are the industry standard format used for PCB fabrication. They contain all the necessary information required to manufacture a PCB, including the copper layers, Solder Mask, silkscreen, and drill holes. Converting an Eagle PCB design to Gerber format is a crucial step in the PCB Manufacturing process.

Why Convert Eagle to Gerber?

Converting Eagle PCB designs to Gerber format is essential for several reasons:

1. PCB Fabrication: PCB manufacturers require Gerber files to produce the physical circuit boards. Without Gerber files, they cannot manufacture the PCB.

2. Standardization: Gerber is the industry standard format for PCB fabrication. It ensures compatibility with various PCB manufacturers and eliminates any ambiguity in the design specifications.

3. Error Prevention: Converting Eagle designs to Gerber allows for a final review of the PCB layout before sending it for manufacturing. This helps identify any errors or issues that may have been overlooked during the design phase.

4. Archiving: Gerber files serve as a backup of the PCB design. They can be easily stored and retrieved for future reference or modifications.

Prerequisites for Converting Eagle to Gerber

Before converting an Eagle PCB design to Gerber, ensure that you have the following:

1. Eagle Software: Make sure you have Eagle installed on your computer. You can download it from the Autodesk website.

2. Completed PCB Design: Ensure that your PCB design is complete and error-free. Double-check the schematic and PCB layout for any mistakes or inconsistencies.

3. Gerber File Viewer: It’s recommended to have a Gerber file viewer installed to review the generated Gerber files. There are several free and paid Gerber viewers available, such as GerbView, ViewMate, and CAM350.

Step-by-Step Guide to Convert Eagle to Gerber

Follow these steps to convert your Eagle PCB design to Gerber format:

Step 1: Open the Eagle PCB Layout

1. Launch Eagle and open the PCB layout file (.brd) that you want to convert to Gerber.

Step 2: Configure the CAM Processor

1. From the top menu, select “File” -> “CAM Processor” to open the CAM Processor window.
2. In the CAM Processor window, click on the “File” menu and select “Open” -> “Job”.
3. Navigate to the Eagle installation directory and open the “cam” folder.
4. Select the “gerb274x.cam” job file and click “Open”. This job file contains the necessary settings for generating Gerber files.

Step 3: Select the Layers to Export

1. In the CAM Processor window, you will see a list of layers that can be exported.
2. Select the layers that you want to include in the Gerber files. Typically, you would include the following layers:
3. Top Copper (Layer 1)
4. Bottom Copper (Layer 16)
5. Silkscreen Top (Layer 21)
6. Silkscreen Bottom (Layer 22)
7. Soldermask Top (Layer 29)
8. Soldermask Bottom (Layer 30)
9. Drill (Layer 44)
10. Make sure the selected layers have a checkmark next to them.

Step 4: Set the Output Directory

1. In the CAM Processor window, click on the “File” menu and select “Output Directory”.
2. Choose the directory where you want to save the generated Gerber files.

Step 5: Generate the Gerber Files

1. Click on the “Process Job” button in the CAM Processor window to generate the Gerber files.
2. Eagle will process the job and create the Gerber files in the specified output directory.

Step 6: Review the Generated Gerber Files

1. Open the generated Gerber files using a Gerber file viewer.
2. Carefully review each layer to ensure that the PCB design is accurate and complete.
3. Check for any missing or incorrect features, such as tracks, pads, or holes.

Step 7: Package and Send the Gerber Files

1. Once you have reviewed and verified the Gerber files, package them together in a compressed file format (e.g., ZIP).
2. Send the packaged Gerber files to your PCB manufacturer for fabrication.

Tips for Successful Eagle to Gerber Conversion

Here are some tips to ensure a smooth and successful conversion from Eagle to Gerber:

1. Use Appropriate Design Rules: Follow the design rules and guidelines provided by your PCB manufacturer. This includes minimum track width, spacing, hole sizes, and other specifications.

2. Perform Design Rule Checks (DRC): Run DRC in Eagle before converting to Gerber. This will help identify any design rule violations and ensure that your PCB layout meets the manufacturing requirements.

3. Use Consistent Units: Make sure that your Eagle design uses consistent units (e.g., millimeters or inches) throughout the schematic and PCB layout. This prevents any discrepancies when generating Gerber files.

4. Include Necessary Layers: Include all the necessary layers in the Gerber files, such as copper layers, solder mask, silkscreen, and drill files. Consult with your PCB manufacturer for their specific requirements.

5. Verify Gerber Files: Always review the generated Gerber files using a Gerber viewer before sending them for manufacturing. This allows you to catch any errors or issues beforehand.

6. Communicate with the PCB Manufacturer: Maintain clear communication with your PCB manufacturer. Provide them with any additional instructions, specifications, or requirements to ensure accurate fabrication of your PCB.

Common Issues and Troubleshooting

1. Missing or Incorrect Layers: If certain layers are missing or incorrect in the generated Gerber files, double-check the layer selection in the CAM Processor. Ensure that the necessary layers are selected and properly configured.

2. Gerber File Compatibility: Some PCB manufacturers may have specific requirements for Gerber file formats. Make sure to generate Gerber files that are compatible with your manufacturer’s specifications. Consult with them if you encounter any compatibility issues.

3. Design Rule Violations: If your Eagle design contains design rule violations, they may cause issues during PCB fabrication. Run DRC in Eagle and resolve any violations before converting to Gerber.

4. Incorrect Units: Inconsistent or incorrect units can lead to manufacturing errors. Ensure that your Eagle design uses consistent units and that the Gerber files are generated with the correct unit settings.

5. Aperture Size Mismatch: Aperture size mismatches can occur if the aperture list in the Gerber files does not match the actual sizes used in the Eagle design. Double-check the aperture sizes and make necessary adjustments in Eagle or the CAM Processor.

Frequently Asked Questions (FAQ)

1. Can I use other CAM job files instead of gerb274x.cam?
   Yes, you can use other CAM job files that are compatible with your PCB manufacturer’s requirements. Some manufacturers may provide their own CAM job files or have specific settings that need to be used.

2. What should I do if my PCB manufacturer requires additional files?
   If your PCB manufacturer requires additional files, such as drill files or netlist files, you can generate them using the CAM Processor in Eagle. Consult with your manufacturer for their specific requirements and configure the CAM Processor accordingly.

3. How do I generate Gerber files with different units?
   To generate Gerber files with different units (e.g., millimeters or inches), you can modify the unit settings in the Eagle design. Go to “Options” -> “User Interface” and select the desired unit. Then, regenerate the Gerber files using the CAM Processor.

4. Can I use Eagle’s built-in Gerber viewer?
   Yes, Eagle has a built-in Gerber viewer that allows you to preview the generated Gerber files. However, it is recommended to use a dedicated Gerber viewer for a more comprehensive review and analysis of the Gerber files.

5. What if I encounter issues with the generated Gerber files?
   If you encounter issues with the generated Gerber files, such as incorrect layers or design rule violations, double-check your Eagle design and the CAM Processor settings. Make sure that the necessary layers are selected and that the design meets the manufacturing requirements. If the issues persist, consult with your PCB manufacturer for assistance.

Conclusion

Converting Eagle PCB designs to Gerber format is a critical step in the PCB manufacturing process. By following the step-by-step guide and considering the tips and common issues mentioned above, you can ensure a smooth and accurate conversion from Eagle to Gerber.

Remember to review the generated Gerber files thoroughly using a Gerber viewer and communicate any specific requirements or instructions to your PCB manufacturer. This will help minimize errors and ensure successful fabrication of your PCB.

With practice and attention to detail, converting Eagle designs to Gerber will become a straightforward process, enabling you to bring your electronic projects to life.

Table 1: Common layers to include in Gerber files

By including these layers in your Gerber files, you provide the PCB manufacturer with the necessary information to fabricate your PCB accurately.

Happy PCB designing and manufacturing!