PCB Fabrication error ?

[veedub565]

Someone gave me the files to get a PCB made up, I went with ALLPCB, submitted my files, but now I've had an email from them

"Dear client, Here is the system notice regarding your PCB item H2W-339492 We need your help to confirm for the below issues :
________________________________________
There is no solder mask layer in your file， but you chose solder mask color for your order. Please kindly advice how should we fabricate?

________________________________________
We didn't find drills layer in your file， please kindly check and provide the file in the format of R274-X."

I thought I'd sent them all the files, so I don't really understand what I've done wrong. I've attached the files I sent them to this post.

I've not done this before

[thm_w]

I tried to open the zip in pcbway online gerber viewer and I don't see any soldermask showing up either. What software did you use to generate it? What settings?

If its something like eagle you can find user defined configurations that are setup to be used with pcbway/allpcb/etc. that should work.
Usually its safest to just send all generated files. Most likely you missed some.

[langwadt]

check that you named the different files as they expect

[bpiphany]

The zip file contains two gerber files, Copper1 and Copper2. I guess it would be "obvious" that the ground plane goes on the bottom.

There is a drill file, which I would have though should be ok. There are no gerber files for solder mask layers.

The mk2.LAY file is from Sprint Layout(?). I can't tell exactly what information is in that. Is ALLPCB claiming to be able to import that?

Code: [Select]

$ ls /tmp/PCB1
Copper1.GBR  Copper2.GBR  mk2.LAY  sq.drl


[veedub565]

There is another file (attached) is this what they are looking for ?

[bpiphany]

That file only contains some more documentation. It's still the same copper layers and drill file. One of the layers is mirrored compared to the other and the drill positions though. That may be why they don't think the drill file is correct.

Still no solder mask. But the word document in the new archive has an image of the board. It almost looks like the top solder mask extends across everything, including pads. The question remains of what the bottom side looks like.

Or there is no solder mask at all, just the copper looking very white.

[wraper]

There is one Gerber file per layer. Obviously with only 2 Gerber files for copper, there cannot possibly be solder resist layers. You should open .lay file with Sprint Layout and check if it can be exported to Gerber properly or design is broken to begin with.

[veedub565]

Yes I see what you are saying, it looks as though the solder mask extends across the whole of the top of the board. There would be no solder topside on this board, all the soldering is underneath. Unfortunatly I don't have a picture of that. Maybe bottomside is just bare copper

I don't quite understand why there can be no solder resist layer with two gerber files ? wouldn't you have a separate gerber file for each layer ?

[wraper]

Yes I see what you are saying, it looks as though the solder mask extends across the whole of the top of the board. There would be no solder topside on this board, all the soldering is underneath.

You still need solder mask layer for it to be produced. And it does not work like this, any hole which is soldered must not be covered with solder mask on any side.

wouldn't you have a separate Gerber file for each layer ?

That's what I already said. Gerber file cannot contain multiple layers. You need separate file for each layer. You need at least 5 files for 2 layer PCB with solder mask, 4 Gerber files and 1 drill file. There can be additional Gerber files, like silkscreen, outline or mechanical layer.

[wraper]

Exported with all required layers for you. However this PCB is strange. It was obviously made for DIY etching without hole metallization since many pads lack copper on top side. However one hole lacks copper on bottom side, which together with inconsistent use of pads on top side and ugly traces indicates a very low quality of design.
EDIT: on further inspection, design is outright broken. Since many holes go straight through copper pour to which they must not be connected. I suggest not producing this trash or at least redesigning it properly first.
EDIT2: also it's mirrored but it can be fixed during gerber export. Together with removal of copper pour this may have some chance of working. However IMHO it should be done by whoever sent you those files. And don't use attached gerber files for production because of issues mentioned.

[wraper]

Just spent some effort to quickly fix this crap, then realized that all holes are 0.6mm 

[veedub565]

Many thanks for making the effort to take a look at it.

I was hoping this might be a simple case of sending the files off to be manufactured. Clearly there's more work to be done on this project. Looks like I'm going to have to get a copy of the software and learn how to do it myself. I've got a schematic and component layout from the service manual, sounds like it's going to be better to start again with this.

[bpiphany]

It's a fairly simple layout and very standard components. It should be easily replicated in any free CAD tool. I would of course suggest KiCAD. Place footprints, make sure to replicate traces, you're good to go, more or less.