Why is my board coming out misaligned?
Many new engineers send their PCB designs straight to the manufacturer after finishing the layout—only to receive boards with incorrect outline dimensions. The likely reason? You sent only the Gerber files and forgot the mechanical drawing (DXF).
Without a DXF file, the manufacturer has no choice but to route the board edges based on the copper layer, which is imprecise. Key takeaway: whenever your design involves outline cutting, always provide a separate DXF structural file that clearly indicates which lines are the inner frame and which are the outer frame. Do this, and you'll reduce outline-related communication issues to nearly zero.
Don't just say "green" when specifying solder mask color
There's more than one kind of green: dark green, light green, matte green, photosensitive green, and more. If your PCB is part of a visible, aesthetic enclosure, color mismatch can be a nightmare.
If color matters to you, request a color sample from the manufacturer or specify a Pantone code. If you have no special requirement, simply write “standard green accepted” in the remarks. That way, the manufacturer will use their standard ink—fast, and far less prone to error.
What is a "PCB Manufacturing Instruction"?
Think of it as your board's ID card. Many beginners make the mistake of sending an email that just says, “Please proceed with production.” That's a big no-no.
You should include a TXT file inside the Gerber folder, specifying:
Board name and revision number
Quantity
Special requirements (e.g., “this hole needs to be plugged,” “apply a label on this side”)
With this info in place, the production team knows exactly what to do. Without it, they're left guessing—and if they guess wrong, you pay the price.
Don’t be afraid to ask “why”
When the manufacturer asks something like, “Your trace width is very thin—should we widen it?” don’t just reply with “No.” Ask them why. Your design might be pushing the limits of their equipment. One extra question could save an entire batch.
Frequently Asked Questions
Q: What is V-cut?
A: It’s a V-shaped groove cut into the board to make it easier to separate after production. If the board is too thin (less than 0.8mm), V-cutting is usually not recommended—it can cause breakage. In such cases, routed slots are a better option.
Q: Why do pads on ENIG boards sometimes fall off?
A: This can happen due to oxidized nickel or insufficient gold thickness—commonly referred to as “black pad.” When placing your order, ask the manufacturer to control the phosphorus content and nickel thickness. This helps reduce the risk significantly.
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