Troubleshooting se-rm PlotManager GERBER: Common Issues & Fixesse-rm PlotManager GERBER is a specialized tool used to create GERBER files for PCB fabrication. While it streamlines the process of converting design data to fabrication-ready outputs, users sometimes encounter issues that can delay production. This article walks through common problems, their likely causes, and practical fixes — from file generation errors to layer mismatches and aperture issues.
1 — Understanding GERBER basics (short primer)
GERBER files describe 2D graphics (copper, solder mask, silkscreen, drill data) used by manufacturers. Modern workflows use RS-274X (extended) GERBER that embeds aperture definitions. Problems often arise from incorrect layer mapping, misconfigured apertures, or mismatches between drill and plot outputs.
2 — Common issue: Missing or empty layers in output
Symptoms
- One or more expected GERBER files are missing.
- A GERBER file exists but contains very little or no drawing data.
Likely causes
- Layers not enabled or mapped correctly in PlotManager.
- Design objects unintentionally assigned to a different layer.
- Layer filters or visibility settings excluded elements during export.
Fixes
- Verify layer mapping: open PlotManager’s layer mapping dialog and ensure each PCB layer (Top Copper, Bottom Copper, Solder Mask, Silkscreen, Mechanical layers) is mapped to a GERBER output.
- Check object layers: in your PCB editor, select objects and confirm their assigned layer. Move misplaced objects to the correct layer.
- Disable any active visibility filters or clipping regions before export.
- Re-export single layers to isolate which layer is causing the problem.
Example steps
- In PlotManager, click “Layer Mapping” (or similar).
- Ensure Top/Bottom Copper, Solder Mask, Silkscreen are checked and assigned proper file names.
- From the PCB editor, run a layer-by-layer visibility check and reassign objects if needed.
3 — Common issue: Incorrect apertures or aperture-related errors
Symptoms
- Gerber viewer shows missing pads or outlines appear as raster shapes.
- Export reports show aperture table errors or “undefined aperture” warnings.
Likely causes
- Using old RS-274-D output (separate aperture files) or incorrect aperture table generation.
- Complex polygons or tiny features that require aperture macros not supported by current settings.
Fixes
- Use RS-274X (extended GERBER) output if PlotManager supports it — this embeds aperture definitions and avoids separate aperture tables.
- If RS-274D is required, ensure the aperture table (.apt) is correctly generated and referenced.
- Increase precision (coordinate format) and ensure unit settings (inch/mm) match your design.
- Convert tiny polygons or thermal spokes into simpler primitives that export cleanly, or adjust minimum aperture sizes.
- For features requiring aperture macros, confirm PlotManager’s macro library includes those macros or switch to primitives.
Practical check
- In export options, set format to RS-274X and set coordinate format to e.g., 4:6 (or as required by manufacturer). Re-export and inspect with a Gerber viewer.
4 — Common issue: Misaligned layers or coordinate shifts
Symptoms
- When opening multiple GERBER files in a viewer, layers are offset or rotated.
- Drill files don’t align with copper layers.
Likely causes
- Different origin or coordinate formats used between layers or between GERBER and drill files.
- Mirroring applied incorrectly to bottom layers.
- Units mismatch (inches vs mm) during export.
Fixes
- Set a consistent datum/origin in PlotManager and the PCB editor prior to export. Use board origin (0,0) and avoid per-layer offsets.
- Ensure all outputs use the same coordinate format and units. Confirm the drill file (Excellon) uses the same origin and is not using relative offsets.
- For bottom layers, export mirrored output only if recommended by your fabricator; many modern workflows expect non-mirrored GERBERs for bottom layers with a viewer applying the mirror.
- Re-export using consistent settings and re-open in the viewer before sending to fabrication.
Quick verification
- Open the top copper and drill files together in a Gerber+Drill viewer. If offsets persist, check units and origin settings in both PlotManager and the drill export dialog.
5 — Common issue: Thermal spokes, hatched pours, and filled polygons exporting poorly
Symptoms
- Thermal spokes disappear or show as solid fills.
- Pour areas are missing or show strange patterns.
Likely causes
- Polygon fill styles or pour algorithms not supported by Gerber output settings.
- Too-small features removed by aperture minimum size rules.
Fixes
- Convert thermals to explicit copper pours with adequate clearance and spoke width that match minimum aperture settings.
- Increase polygon pour resolution or choose an export option that preserves polygon geometry rather than approximating with apertures.
- Check for “remove small features” or “minimum aperture” settings and lower the threshold if the fabricator can handle smaller features.
- For hatched pours, consider exporting polygon as solid or subdividing into manufacturable primitives.
6 — Common issue: Drill issues (missing holes, wrong sizes, or misformatted Excellon)
Symptoms
- Excellon file missing certain hole sizes.
- Fabricator reports drill coordinate or tool number errors.
Likely causes
- Drill hits assigned to non-drill layers or via types not included in drill output.
- Excellon format mismatch (e.g., using old-format headers, wrong tool numbering).
- Unit/origin mismatch between GERBER and Excellon exports.
Fixes
- Ensure all hole types (thru-holes, vias, non-plated) are exported and included in the drill file.
- Use modern Excellon output with proper tool table; confirm tool numbers correspond to the expected diameters.
- Match units and origin to GERBER files. If possible, embed tool sizes and use absolute coordinates.
- Test drill file in an Excellon viewer and cross-check a few hole coordinates vs. layout.
7 — Common issue: Silkscreen problems — clipped text or overlapping with pads
Symptoms
- Reference designators cut off or printed over pads.
- Silkscreen appears shifted or missing near SMD pads.
Likely causes
- Silkscreen being exported without preventing printing over pads (fabrication clearance settings).
- Text objects on wrong layers or using fonts/macros not supported by the GERBER export.
- Stroke width or vectorization settings that convert text poorly.
Fixes
- Enable “clip silkscreen to pads” or expansion settings that remove mask/silk around pads (or use the “prevent silkscreen over pads” function).
- Convert text to outlines if fonts are not reliable; ensure font sizes and stroke widths meet manufacturer minimums.
- Move critical reference designators to a mechanical layer reserved for assembly drawings if they should not be on fabrication silkscreen.
- Re-run export and inspect the silkscreen layer in a viewer.
8 — Common issue: File naming, extension, and format expectations from fabricator
Symptoms
- Fabricator rejects files or returns unclear error messages.
- Unexpected file types in the submission (e.g., .PCB vs .GBR).
Likely causes
- PlotManager uses internal naming conventions different from fabricator requirements.
- Fabricator expects combined archives with specific filenames or layer names.
Fixes
- Ask your fabricator for their GERBER naming conventions and preferred format (RS-274X, separate drill, or embedded drill).
- In PlotManager, customize file names and extensions to match the fabricator’s template (e.g., top.gbr, bottom.gbr, boardname_GTL.gbr).
- Bundle files into a ZIP and include a README listing which files correspond to which layers.
Suggested standard filenames
- boardname_GTL.gbr (Top Copper)
- boardname_GBL.gbr (Bottom Copper)
- boardname_GTS.gbr (Top Soldermask)
- boardname_GBS.gbr (Bottom Soldermask)
- boardname_GTO.gbr (Top Silkscreen)
- boardname_GBO.gbr (Bottom Silkscreen)
- boardname_DRL.xln (Drill/Excellon)
9 — Common issue: Rasters or embedded bitmap objects exporting as low-quality or missing
Symptoms
- Logos or bitmaps appear pixelated or don’t show in GERBER viewer.
- File size or output reports indicate conversion errors.
Likely causes
- PlotManager converts bitmaps to vector primitives or rasterized images that GERBER viewers handle inconsistently.
- Bitmaps exceed resolution limits or use unsupported color depths.
Fixes
- Convert logos to vector outlines (preferred) before export.
- If raster is necessary, ensure resolution is high enough and convert to the format PlotManager recommends for GERBER export.
- Test the exported GERBER in multiple viewers or provide the fabricator with a separate high-resolution artwork file.
10 — Diagnostic workflow: How to isolate and fix problems step-by-step
- Reproduce the problem with a minimal test board (one or two layers).
- Export one layer at a time and inspect in a Gerber viewer.
- Compare coordinates, units, and origins between GERBER and drill files.
- Toggle RS-274X vs RS-274D output and check aperture tables.
- Convert problematic objects (text, bitmaps, polygons) to simpler primitives and re-export.
- If issue persists, provide your fabricator with the test GERBER set and ask for their exact error logs or expectations.
11 — Preventive best practices
- Always use RS-274X (extended GERBER) when possible.
- Keep consistent units and origin across all outputs.
- Name files clearly following fabricator conventions.
- Convert fonts to outlines and prefer vector logos.
- Check minimum aperture and trace/clearance rules against your fabricator’s capabilities.
- Run a Gerber + Drill viewer check before submission.
12 — When to contact support or your fabricator
Contact support when:
- Export produces internal errors or crashes.
- You can’t locate layer mapping or export settings in PlotManager.
- Fabricator provides error logs you can’t interpret.
Contact fabricator when:
- They reject files with specific format/coordinate complaints.
- They require specific naming or unit conventions.
- They confirm the files are fine on their end — then suspect a viewer issue.
13 — Useful quick-check checklist (copyable)
- [ ] Use RS-274X format
- [ ] Consistent units and origin for GERBER and drill files
- [ ] Layer mapping verified
- [ ] Aperture table valid (or embedded)
- [ ] Silkscreen clipped from pads as needed
- [ ] Drill tool sizes and numbers match Excellon table
- [ ] Logos converted to vectors or high-res rasters
- [ ] File names follow fabricator convention
- [ ] Test in a Gerber viewer before upload
If you want, I can: export a concise troubleshooting checklist tailored to your fabricator’s specs, analyze an exported GERBER set (you paste file contents or describe errors), or write a step-by-step export guide for a specific PCB tool paired with se-rm PlotManager.
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