PCB Files for Manufacturing: What to Send and What to Check

A PCB file can mean a native design file, a Gerber package, drill data, assembly files, or a full manufacturing exchange format.

For production, don't rely on one .pcb, CAD, or PDF file alone.

A complete handoff includes verified fabrication files, drill files, a fabrication drawing, and — when assembly is needed — BOM and pick-and-place data. A file that looks complete on your end may not be complete enough for quotation, fabrication, SMT assembly, or mass production.

What Is a PCB File?

A PCB file is any digital file used to design, describe, fabricate, assemble, inspect, or test a printed circuit board.

The confusing part is that "PCB file" does not refer to only one format. It can mean the original design file from EDA software, the manufacturing files sent to a factory, or assembly documents like BOM and pick-and-place files.

From a factory point of view, the file extension matters less than the production information inside the package. Here is what each type actually does:

File Type	Example Format	Main Use
Native PCB design file	.pcb, .PcbDoc, .brd, .kicad_pcb	Editing and design review
Gerber files	.gbr, .gtl, .gbl, .gts, .gbo	PCB layer data for fabrication
NC drill files	.drl, .xln	Hole and drill data
Fabrication drawing	PDF, DXF, DWG	Human-readable build notes
BOM	.csv, .xlsx	Component purchasing and assembly
Pick-and-place file	.csv, .txt	SMT placement position and rotation
ODB++ / IPC-2581	Structured manufacturing package	Richer production data exchange

A production handoff usually combines design reference, fabrication data, drill files, and assembly data.

Ucamco describes Gerber as a standard format for PCB design data transfer — which is why it is still the most common format you send to board factories. But Gerber is only one part of the handoff.

The real question is: can the factory quote, build, inspect, and assemble the board without guessing?

Native PCB Files Are Not the Same as Manufacturing Files

Native PCB files are useful for editing and review. Manufacturing files are what the factory needs to actually build the board.

A factory usually needs exported production data, not just the original design file. A .PcbDoc, .brd, or .kicad_pcb file may contain the full design — but it is still tied to the EDA software that created it. Version differences, missing libraries, and unclear export options can change how the file looks on the other side.

Manufacturing outputs are different. They are exported specifically for CAM, drilling, routing, solder mask, silkscreen, assembly, inspection, and test.

Altium's manufacturing documentation separates design work from manufacturing outputs for this reason. The editable design file is not the same as the production release package.

When you're not sure what to send:

• include the native file as a reference if it's available
• send Gerber or supported manufacturing data for production
• include drill files
• include a fabrication drawing
• include assembly files if SMT is required

That removes the guesswork on both sides.

Why Sending Only One .pcb File Can Be Risky

In one Lumina project, a customer sent a native .pcb file. The design looked finished on their end. When the factory opened it, two pads were missing.

The issue did not reach production that time. But it exposed something worth understanding: the file the customer believed they sent was not exactly the file the factory saw after opening it.

A native PCB file can display differently after version conversion or import, so production outputs should be cross-checked before release.

Native files are tied to the EDA software that created them. Version differences, missing libraries, different layer settings, or unclear export options can change how a file looks on the other side. In some projects, the difference is only found during CAM review.

For a sample order, that delay lands on your schedule. For a repeat LED board, it can create confusion between revisions at exactly the wrong time.

Send the native .pcb file as a backup reference if you want — but send the actual production package separately: exported fabrication files, drill files, drawings, and assembly data if needed.

Before sending, open the exported files in a Gerber viewer and compare them against the design. This catches missing pads, outline errors, and drill alignment problems before the file reaches the factory.

What Files Are Needed for PCB Fabrication?

For PCB fabrication, send Gerber files, drill data, a board outline, and a fabrication drawing with your build requirements.

Gerber files alone are enough for a first review — but not for production. The factory also needs hole data, mechanical details, surface finish, thickness, and special notes.

File / Note	What It Tells the Factory	When It Is Needed
Gerber layers	Copper, solder mask, silkscreen, paste, and other layer images	Almost every fabrication order
NC drill file	Hole sizes and locations	Boards with holes, vias, slots, or mounting holes
Rout / profile data	Board outline, slots, cutouts, panel profile	Non-rectangular boards or panelized boards
Fabrication drawing	Thickness, stackup, finish, tolerances, notes	Production release, special requirements
Netlist / test notes	Electrical checking reference	When requested or for more controlled builds

Gerber is common because nearly every factory can process it. But Gerber describes layer images, not build specs — which is why the fabrication drawing still matters.

For LED aluminum PCB fabrication, your drawing or order notes should also confirm board thickness, copper thickness, surface finish, solder mask, and any special mechanical requirements. If the project is for aluminum PCB fabrication, don't send copper artwork alone and assume the factory will infer the rest.

Quotation may start with partial files. Production should not.

What Files Are Needed for PCB Assembly?

If you're ordering assembly, Gerber files alone are not enough. The assembler also needs component and placement data — especially for turnkey SMT assembly.

Gerbers show the board. They don't tell the assembler which LED, resistor, connector, or IC goes on each reference designator.

For bare PCB fabrication: send Gerber, drill, outline, and fabrication drawing. The most common missing item is the drill file or a clear surface finish note.

For SMT assembly: also include BOM, pick-and-place file, assembly drawing, and polarity notes. Rotation and polarity are the most common points that need clarification.

For turnkey PCBA: combine both sets and add sourcing notes — including approved alternates or exact MPNs if substitution is not allowed.

If testing or inspection is part of the project, include test point references and acceptance criteria.

PCB assembly needs the fabrication package plus component, placement, polarity, and sourcing data.

Your BOM should include reference designators, quantities, part numbers, and approved alternatives. Your pick-and-place file should include X/Y position, rotation, side, and reference designator.

Altium's assembly output documentation covers pick-and-place output formats in detail.

For LED boards, polarity deserves extra attention. LED direction, diode polarity, IC pin 1, electrolytic capacitors, and connector orientation should be clear in the assembly drawing or notes.

If assembly is part of the order, link the file package to your SMT assembly for LED aluminum PCB requirements. For a full sourcing and placement project, the same applies to turnkey PCB assembly.

Gerber, Drill, ODB++, and IPC-2581 in Plain Terms

Gerber and NC drill files are the most widely accepted baseline — nearly every factory can process them. ODB++ and IPC-2581 carry richer manufacturing data, but the right choice depends on what your factory can actually handle.

Gerber describes each layer as an image. It is easy to inspect with a viewer and universally supported, but it needs drill files and a fabrication drawing to carry the full build intent.

NC drill files define hole coordinates and sizes. They are not optional — without them, the factory cannot drill your board.

ODB++ and IPC-2581 bundle fabrication, assembly, and test data into a single structured package. When the factory supports them, they reduce back-and-forth. When the factory does not, they create confusion.

Use the format your factory confirms, and include drawings or notes when the format does not carry enough production intent. A rich format is only useful if both sides can open and read it the same way.

Are CAD Drawings or PDFs Enough for PCB Production?

No — but they are still worth including.

Some customers send a DWG drawing and assume the factory will build the board from it. A drawing can describe a shape and list dimensions. It cannot replace Gerber layer data, drill files, BOM, or pick-and-place data — the machine-readable formats that drive fabrication and assembly.

A fabrication drawing PDF can carry board thickness, tolerances, surface finish, and special notes that Gerber files alone do not. An assembly drawing PDF can clarify polarity and placement intent. Both support the file package. Neither replaces it.

If you only have CAD drawings, the design still needs to be exported into proper PCB manufacturing data before production can start.

Extra File Details for LED Aluminum PCB Orders

If you're ordering an LED aluminum PCB or MCPCB, your file package needs more than copper artwork.

The aluminum base, dielectric layer, copper thickness, surface finish, and assembly requirements all affect the final product — and most of these are not captured in the Gerber files themselves.

Detail	Why It Matters
Finished board thickness	Affects structure fit and mechanical support
Copper thickness	Affects current capacity and cost
Aluminum base thickness	Affects strength and heat spreading
Dielectric thermal conductivity	Affects heat transfer from circuit to aluminum
Dielectric thickness	Affects insulation and thermal path
Surface finish	Affects solderability and storage life
Solder mask / silkscreen	Affects appearance, marking, and assembly clarity
Quantity and lead time	Affects material planning and production schedule

If you're ordering LED lighting boards from Lumina, these details should be reviewed together with the aluminum PCB dielectric and repeat-order requirements. A standard board covered in our aluminum PCB guide may look simple from the Gerber file — but your quote can still be delayed if thickness, copper, surface finish, quantity, or thermal requirement are unclear.

For assembly orders, also include:

• LED BOM
• pick-and-place file
• polarity notes
• assembly drawing
• test requirements if needed

The same Gerber package can lead to different quotes if the material and process details are not specified.

What to Check Before Sending PCB Files to a Factory

Before you send, confirm that your exported manufacturing data matches the design intent and that all files belong to the same revision. A file review takes minutes; a production delay does not.

Check Item	Why It Matters	Common Issue
Board outline	Defines final shape and routing	Missing or wrong mechanical layer
Drill file	Controls holes and vias	Drill file not exported or wrong units
Layer alignment	Prevents copper, mask, and drill mismatch	Mirrored or shifted layer
Solder mask	Affects soldering and exposed copper	Missing mask opening or wrong side
Silkscreen	Helps assembly and marking	Text over pads or missing polarity mark
Pads and footprints	Affects soldering and placement	Missing pads after file import
BOM revision	Controls component sourcing	BOM does not match Gerber revision
Pick-and-place	Controls SMT placement	Rotation or side not clear

Check the exported package in a viewer, then confirm that the Gerber, drill, BOM, and placement files use the same revision.

Open the exported Gerber or supported manufacturing package in a viewer. Check the board outline, drill holes, slots, solder mask, silkscreen, missing pads, units, scale, and polarity. Then compare the output against the source design or PDF drawing.

If assembly is required, confirm your BOM and pick-and-place file match the same revision as the Gerbers.

For a new LED aluminum PCB project, include a short readme or drawing note listing board thickness, copper thickness, surface finish, quantity, lead time, and any special assembly requirements.

Small checks before quotation often prevent bigger discussions after production has started.

Conclusion

A PCB file is not always a production-ready file.

The most common mistake is not a wrong format — it is an incomplete package. You send Gerbers, assume the factory has everything, and the question comes back days later: drill data is missing, surface finish is unclear, or the BOM does not match the revision.

Think in terms of a handoff, not a file. Fabrication files, drill data, a drawing, and assembly documents if SMT is involved. For LED aluminum PCB, add the thermal and build specs.

If you are not sure whether your file package is complete, send it to Lumina before quoting. We can review the package and identify what may still need confirmation.