Gerber File Checklist: What to Check Before Ordering PCBs

A successful PCB order starts with a manufacturing package that tells one consistent story. Before uploading a ZIP file, take a few minutes to review exactly what the fabricator will receive.

Start with one released revision

Create a fresh export folder for the board revision you intend to build. Mixing yesterday’s drill data with today’s copper layers can produce a package that looks complete but contains conflicting information. Give the archive a recognizable project name and revision, then keep a copy with your project records.

Check the manufacturing outputs

Gerber files describe the plotted board layers. Hole information is commonly supplied as separate drill data. KiCad, for example, provides separate plotting and drill-file export tools, and its Gerber viewer can help you inspect the resulting files.

• Board outline: check that the intended shape and internal cutouts are clear.
• Copper layers: confirm that every intended copper layer is present and in the correct stack order.
• Mask and legend: inspect the solder-mask openings and confirm that component labels remain readable.
• Holes and slots: include the required drill outputs and clearly communicate plated versus non-plated features.

Review the export, not just the design

Open the exported package in a viewer. Compare the board dimensions with your order and inspect a few recognizable features, such as mounting holes and connectors. This is a useful final check for alignment or an accidentally omitted layer; it is not a substitute for design-rule checking or engineering review.

Make special requirements explicit

Write down requirements that are easy to miss in artwork alone: finished thickness, copper weight, material, surface finish, or any controlled-impedance requirement. Ask the manufacturer to resolve unclear details before production instead of relying on a filename to explain them.

Technical references: KiCad PCB Editor documentation: fabrication outputs and drill files; KiCad Gerber Viewer. This article is a preparation guide; confirm the required deliverables for your order.