Standard Gerber declared obsolete

The End of an Era for Gerber Files

In a major announcement that has sent shockwaves through the electronics industry, the standard Gerber file format, which has been used for decades to describe the printed circuit board (PCB) and related electronic files, has officially been declared obsolete. This move marks the end of an era and signals a significant shift towards more modern and efficient file formats for electronics design and manufacturing.

What are Gerber Files?

Gerber files, named after the Gerber Scientific Instrument Company, have been the de facto standard for describing the printed circuit board (PCB) and related electronic files since the 1980s. These files contain the necessary information for PCB Fabrication, including the copper layers, solder mask, legend, and drill data.

Gerber files use a vector image format where the PCB design is represented by a series of commands that define the coordinates and apertures for each layer. Each layer of the PCB, such as the top and bottom copper layers, solder mask, and silkscreen, is described in a separate Gerber file.

For decades, Gerber files have been the primary means of communication between PCB designers and manufacturers. However, as PCB designs have become more complex and the demands for higher precision and efficiency have increased, the limitations of Gerber files have become more apparent.

The Limitations of Gerber Files

While Gerber files have served the electronics industry well for many years, they have several inherent limitations that have led to their obsolescence. Some of the key limitations include:

1. Lack of Intelligence: Gerber files are essentially “dumb” image files that do not contain any intelligent information about the PCB design. They do not include any information about the components, nets, or design intent, which can lead to ambiguity and errors in the manufacturing process.

2. Limited Layer Support: Gerber files are limited in the number of layers they can support. While this was sufficient for simpler PCB designs in the past, modern high-density designs often require dozens or even hundreds of layers, which Gerber files cannot handle efficiently.

3. No 3D Support: As PCB designs have become more complex, there has been an increasing need for 3D visualization and analysis. However, Gerber files are strictly 2D and do not provide any 3D information, making it difficult to detect and resolve design issues related to component placement, clearances, and mechanical fit.

4. Inefficient Data Transfer: Gerber files are notoriously large and inefficient for data transfer. Each layer of the PCB requires a separate file, which can lead to a proliferation of files and make data management and version control challenging.

5. Lack of Standardization: While Gerber files are considered a “standard” format, there is no official governing body or specification for the format. This has led to variations and inconsistencies in how Gerber files are generated and interpreted by different software tools and manufacturers.

The Rise of Modern File Formats

To address the limitations of Gerber files and meet the demands of modern electronics design and manufacturing, several new file formats have emerged in recent years. These formats offer significant advantages over Gerber files in terms of intelligence, efficiency, and standardization.

Some of the most notable modern file formats include:

1. ODB++: The ODB++ (Open Database++) format, developed by Mentor Graphics (now part of Siemens), is a comprehensive and intelligent format that includes all the necessary information for PCB fabrication and assembly in a single file. ODB++ files contain detailed information about the PCB design, including net connectivity, component placement, and design rules, making it easier to detect and resolve design issues early in the process.

2. IPC-2581: The IPC-2581 format, developed by the IPC (Association Connecting Electronics Industries), is an open, neutral format that aims to standardize the exchange of PCB design data. IPC-2581 files include intelligent information about the PCB design, such as net connectivity and component attributes, and support 3D visualization and analysis.

3. Gerber X2: Gerber X2 is an extension of the traditional Gerber format that adds intelligence and functionality to the files. Gerber X2 files include additional information such as pad functions, net connectivity, and layer stackup data, making them more useful for advanced PCB designs.

As the table above shows, modern file formats like ODB++ and IPC-2581 offer significant advantages over traditional Gerber files in terms of intelligence, 3D support, efficiency, and standardization. These formats are better suited to the complex demands of modern PCB design and manufacturing.

The Impact on the Electronics Industry

The obsolescence of Gerber files and the shift towards modern file formats is having a significant impact on the electronics industry. PCB designers, manufacturers, and software vendors are all adapting to this change and updating their tools and processes accordingly.

For PCB designers, the move away from Gerber files means learning new design tools and methodologies that support modern file formats. Designers will need to become familiar with the intelligent features and capabilities of formats like ODB++ and IPC-2581, and adapt their design practices to take full advantage of these features.

PCB manufacturers will also need to update their processes and equipment to handle modern file formats. This may require investments in new software tools and machinery, as well as training for personnel. However, the benefits of modern file formats, such as improved efficiency and fewer manufacturing errors, are expected to outweigh the costs in the long run.

Software vendors are also responding to the shift towards modern file formats. Many popular PCB design tools, such as Altium Designer and Cadence Allegro, now support exporting to formats like ODB++ and IPC-2581. In addition, new software tools are emerging that are specifically designed to work with modern file formats, such as Siemens’ Valor NPI software for ODB++ data management.

Frequently Asked Questions (FAQ)

1. What does it mean that Gerber files are obsolete?

Gerber files being declared obsolete means that they are no longer considered the standard or preferred format for describing PCB designs and related electronic files. While Gerber files may still be used in some cases, the industry is shifting towards more modern and intelligent file formats like ODB++ and IPC-2581.

2. Can I still use Gerber files for my PCB designs?

Yes, you can still use Gerber files for your PCB designs, and many manufacturers will still accept them. However, it is recommended to start transitioning to modern file formats to take advantage of their benefits and stay current with industry trends.

3. What are the advantages of modern file formats like ODB++ and IPC-2581?

Modern file formats offer several advantages over Gerber files, including:
– Intelligent information about the PCB design, such as net connectivity and component attributes
– Support for 3D visualization and analysis
– Improved efficiency and fewer manufacturing errors
– Better standardization and consistency across the industry

4. Do I need to learn new PCB design tools to use modern file formats?

Not necessarily. Many popular PCB design tools, such as Altium Designer and Cadence Allegro, now support exporting to modern file formats like ODB++ and IPC-2581. However, to take full advantage of the intelligent features of these formats, you may need to learn new design methodologies and best practices.

5. Will the shift to modern file formats increase the cost of PCB manufacturing?

In the short term, the shift to modern file formats may require some investments in new software tools and equipment for PCB manufacturers. However, in the long run, the benefits of modern file formats, such as improved efficiency and fewer manufacturing errors, are expected to outweigh the costs and lead to overall cost savings for the industry.

Conclusion

The obsolescence of Gerber files marks a significant milestone in the evolution of the electronics industry. As PCB designs become more complex and demanding, the limitations of Gerber files have become increasingly apparent, necessitating a shift towards more modern and intelligent file formats.

While the transition to formats like ODB++ and IPC-2581 may require some adaptation and investment in the short term, the long-term benefits are clear. These formats offer improved intelligence, efficiency, and standardization, enabling faster and more reliable PCB design and manufacturing.

As the industry continues to evolve, it is essential for PCB designers, manufacturers, and software vendors to stay current with the latest trends and technologies. By embracing modern file formats and adapting to new design methodologies, the electronics industry can continue to innovate and meet the ever-increasing demands of the digital age.