PCB Assembly Services - Screaming Circuits: Electronics Manufacturing Files - What We Need

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Electronics Manufacturing Files - What We Need

Manufacturing is all about taking data from you and delivering some good working circuit boards. Well, it can be just data - as in full turn-key, or data plus some parts and or PC boards, as in a partial turn-key or a kitted job. Regardless of whether you're sending parts and boards, or having us buy everything, we need good data, and a lot of it.

That data is the difference between the working boards you want and need and a random jumble of expensive paper weights. The quality and accuracy of that data is often the difference between boards on time and boards not on time.

We need a bill of materials (BOM), the job specifications (which you give us by ordering and describing any special instructions on our web site), and the CAD design files. Fab and Assembly drawings are always a good idea too. A little extra time spent on the files you send us leads to reduced risk, and that's a very good thing.

The BOM is really the anchor in the files set. We buy parts based in the manufacturer name, component part numbers and quantity. It starts there. Then, the reference designator is our key to putting the part on the board. We match the reference designator to the position and rotation data contained in the other files.

The CAD design files tell us where to put the part and at what angle of rotation to place it. The world of manufacturing files is complex and fractured. Our preferred set would start with intelligent CAD files, such as ODB++ or IPC-2581. Those two are the most modern files and usually contain most or all of what we need. "Usually" is a critical part of the phrase.

Gerbers and a Centroid (AKA pick and place or XYRLS file) are the old standbys. Even though the IPC-2581 and ODB++ are trying to replace the Gerber, we still need the Gerber just in case. If you are use CAD systems such as Eagle CAD or KiCad, we can also use the native CAD board file instead of the other intelligent files.

The ODB++ and IPC-2581 file formats are the future of electronics manufacturing. They come with more data, and more accurate data than do Gerbers. If you can send either of these two, please do so. Even if you have those, you should still send us the Gerber files. Gerbers are the lowest common denominator, and provide a base that we and PCB fab houses can work from. 

Gerber top copper
The Gerbers are a set of files used to create the various layers of the PC board. Each layer requires an individual file, so a six layer board (six copper layers), will typically require at least 13 distinct files: one for each copper layer, top solder mask, bottom solder mask, top silkscreen, bottom silkscreen, the drills holes, and solder paste for the top, and bottom if the board has SMT parts on both sides.

The drill file is combined with the gerbers to line up the via and thru-hole component holes with the appropriate spots in the PC board. Then the pick and place file will tell the assembly house where to put each component, what angle to place it at, and which side of the board it goes in.

Fab drawings hold a human readable, often in PDF format, description of the board and any special instructions needed by the fab house. The assembly drawing would be the same, but for the assembly house.

Sometimes the parts are too densely packed for the reference designators and polarity marks to show up on the actual board, or for aesthetic reasons, the designer doesn’t want them on the board. In such cases, all of that information would be put into a set of assembly drawings - PDF files showing all of the necessary reference information.

The ODB++ and IPC-2581 file formats, as of this writing, still aren’t universally accepted, but are getting more so all the time. Use and promotion of these new intelligent CAD output file formats helps to reduce the number of manual steps and human interpretation, and will eventually lead to better quality and faster manufacturing times.

As you probably gathered while reading this, the world of manufacturing files is complex. Take some extra time and reread this. Then double check your files before sending them off to us. If in doubt, ask.

Duane Benson
What do we need?
What does it really matter?
Matter converts to energy
E=(what we need)C2

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