Sending the Perfect Data Package for PCB Manufacturing at PCB Power

To ensure the highest quality and accuracy in PCB manufacturing, PCB manufacturers require a clean, well-organised Data Package — and understanding exactly what to include (and what to leave out) can make a significant difference to how smoothly your order is processed.

This guide covers everything you need to know: what files to include, which formats we support, and why sending raw Gerber files — without additional formats — is the best approach when working with us.

What Is a Data Package?

A Data Package, commonly referred to as Gerber files, is the complete set of design files that defines every layer of your PCB. Think of it as the blueprint your manufacturer works from — every copper trace, drill hole, solder mask opening, and silkscreen label is communicated through these files.

Getting this package right is critical. Without accurate and complete Gerber files, it is not possible to manufacture a board that matches your design intent — even small inconsistencies can result in electrical issues, incorrect dimensions, or misaligned layers.

What PCB Power Requires in Your Data Package

PCB Power India requires Gerber files in the Standard RS-274X format. Please provide separate Gerber files for each layer of your design. Here is what a complete data package should include:

• Top Copper Layer — defines all top-side copper traces, pads, and fills
• Bottom Copper Layer — defines all bottom-side copper traces, pads, and fills
• Inner Copper Layers — required for multilayer boards (provided as separate files per layer)
• Top Solder Mask Layer — defines solder mask openings on the top side
• Bottom Solder Mask Layer — defines solder mask openings on the bottom side
• Top Silkscreen / Legend Layer — component references, polarity markers, and labels on the top side
• Bottom Silkscreen / Legend Layer — if applicable
• Board Outline / Mechanical Layer — overall board dimensions, slots, cutouts, and edge profile
• Drill File — in Excellon format, covering all through-holes, vias, and (if applicable) blind/buried via pairs
• Technical Specifications — board dimensions, layer count, surface finish, copper weight, and any special requirements

Note on the GKO (Keep-Out) Layer: Your design may include a GKO layer that defines restricted areas for routing or component placement. While this layer is useful during the design phase, it is not required for fabrication and does not need to be included in your submission.

Supported File Format

RS-274X is the only Gerber format we require. It is widely accepted across the industry and eliminates the ambiguity associated with older formats that rely on separate aperture definition files.

A few additional specifications to keep in mind when exporting:

• File Precision: Set your output precision to 4:4 or higher to ensure all design details are captured accurately.
• Naming Convention: Clearly label each file by layer — for example, Top_Copper.gbr, Bottom_Soldermask.gbr — to avoid any confusion during file identification.
• Drill Units: Ensure your drill file and Gerber files are in the same unit system — either both metric (mm) or both imperial (inches). A mismatch in units is one of the most common causes of hole placement errors.

Send Us Raw Gerbers — We Handle the Rest

This is where PCB Power works differently from most manufacturers, and it is important to understand why this benefits you.

We ask that you send us raw, as-exported Gerber files — straight from your EDA tool, without any pre-processing. All of this is handled by our team as part of every order.

PCB Power Provides Full Pre-Production Engineering — As Standard

Most PCB manufacturers take the files you provide and process them directly into production with minimal intervention. At PCB Power, we do things differently.

Every order placed with us goes through a complete pre-production engineering process carried out by our in-house DFM (Design for Manufacturability) review team. This includes:

• DFM Review — your design is checked against industry-standard DFM guidelines and our manufacturing capabilities, covering trace widths, spacing, annular rings, drill-to-copper ratios, solder mask clearances, and more
• Production Data Preparation — our engineers prepare fully production-ready data tailored to our specific equipment and processes.
• Layer Verification — all layers are confirmed to be correctly identified, aligned, and consistent with one another
• Drill-to-Copper Registration — drill placement is verified against copper pads across all layers
• Stack-Up Confirmation — for multilayer boards, the layer stack-up is confirmed against your specified requirements

This pre-production engineering is built into every order at PCB Power, at no additional cost. It means the production data used to manufacture your board is always prepared to our exacting standards.

Because we prepare production data ourselves, all we need from you is your raw, clean Gerber output.

Why Sending Multiple File Formats Creates Problems

It is not uncommon for customers to submit a data package that contains Gerber files alongside an ODB++ package, — with the intention of being thorough. While the intention is understandable, this approach actually introduces risk rather than reducing it.

When multiple file formats are present in a data package, there is always the possibility of inconsistencies between them. An ODB++ package may carry different solder mask expansion settings than the Gerber files. When our engineers encounter conflicting data, every ambiguity must be investigated and resolved before production can begin — which causes delays and, in some cases, can result in the production data not accurately reflecting your design.

To ensure accuracy and avoid any confusion, please submit Gerber files only — no additional formats are necessary.

Our DFM team has everything they need to review and prepare your data from the Gerber package alone. Additional files do not add clarity; they add complexity.

What You Do Not Need to Include

For the avoidance of doubt, here is what you do not need to send with your data package when ordering from PCB Power India:

• ODB++ packages
• IPC-2581 files
• Native EDA design files (.brd, .kicad_pcb, .SchDoc, etc.)

If it is not a Gerber or Excellon drill file, it does not need to be in your submission. Our team will take care of the rest.

Data Package Checklist

Before uploading your files, use this checklist to confirm your data package is complete:

• Top and Bottom Copper Gerbers (plus inner layers if multilayer)
• Top and Bottom Solder Mask Gerbers
• Top Silkscreen Gerber (and Bottom if applicable)
• Board Outline / Mechanical Layer Gerber
• Excellon Drill File(s)
• Files clearly named by layer
• All files in RS-274X format
• All files packaged into a single ZIP archive
• No additional formats included (no ODB++or native EDA files)

Need Help With Your Data Package?

If you are unsure whether your files are correctly prepared, or if you have any questions about our requirements, please do not hesitate to reach out to our technical support team.

Providing a properly formatted Gerber data package allows for a smooth production process and ensures your PCB is manufactured to your exact specifications — and with PCB Power’s pre-production engineering behind every order, you can be confident that your design is in good hands from the moment your files arrive.

Ready to order? Upload your Gerber files and get an instant quote.