FAQ
TL;DR: 1 open‑source option exists—“only one open source program … GerbMerge”—but it isn’t very user friendly; for one‑offs, try timed trial editors or careful manual merges with offsets and drill handling. [Elektroda, Danny Carr, post #21657694]
Quick Facts
- Open-source named tool: GerbMerge; usability is limited for beginners. [Elektroda, Danny Carr, post #21657694]
- Many fabs panelize for free or a nominal charge when you include a drawing. [Elektroda, Gary Crowell, post #21657688]
- Low‑cost “special offer” boards usually forbid customer panelization. [Elektroda, Joe Wolin, post #21657691]
- Policies vary: some allow multi‑design panels; pooled services combine orders; limits may include no ET or rectangular boards only. [Elektroda, Gary Crowell, post #21657693]
- Two commercial tools with panelization/merge wizard: DFM Now! Pro V6 and FAB 3000 Pro V6. [Elektroda, Miranda Yip, post #21657695]
What free/open-source software can panelize Gerber files?
GerbMerge is the only open‑source panelizer named in the thread. The author notes it doesn’t look “very user friendly.” For one‑time needs, timed trial Gerber editors can help. Manual merging is possible but requires offsets, step‑and‑repeat codes, and careful drill file handling. “It’s do‑able but tricky.” [Elektroda, Danny Carr, post #21657694]
Does FreePCB support Gerber panelization?
Yes. A contributor suggests FreePCB and believes it supports panelization of Gerber files. It is not a high‑end tool like Altium Designer, but it may cover basic panelization needs for budget workflows. [Elektroda, Joe Wolin, post #21657687]
Will my PCB manufacturer panelize for me?
Often yes. Many board houses will panelize for free or for a nominal charge if you provide a drawing that shows what you want. This can be faster and safer than DIY merges for newcomers. [Elektroda, Gary Crowell, post #21657688]
Can I mix several different designs on one panel?
Policies differ by fab. One poster explains, “board house panelization is usually always limited to step‑and‑repeat of a single design.” Some shops allow multi‑design panels; others don’t. Limitations can include no electrical test or only rectangular boards. [Elektroda, Gary Crowell, post #21657693]
Why do low‑cost specials often ban panelization?
Low‑cost or promotional board offers usually disallow panelization to keep throughput and panel utilization predictable. If you’re targeting the cheapest tier, expect a one‑design‑per‑order rule. [Elektroda, Joe Wolin, post #21657691]
How do I panelize Gerbers in Altium or a Gerber tool (quick steps)?
- Import your Gerber file(s) into the tool.
- Open Tools > Penalize > Simple (or equivalent) and set image spacing and number of copies.
- Generate the panelized output files for fabrication.
These steps were shared for Altium/“Gerber tools.” [Elektroda, Rajesh Kumar, post #21657697]
Can CAM350 merge several different boards into one file?
Yes. A responder confirms CAM350 can panel several different boards into one file. They also caution that if you panel too many different boards, setup costs can be very high, which may negate savings. [Elektroda, Liberty Zhang, post #21657696]
Are there affordable commercial tools with a panelization wizard?
Yes. Numerical Innovations offers two products—DFM Now! Pro V6 and FAB 3000 Pro V6—that include a Panelization/Merge Wizard and more. That’s two supported commercial options if open source doesn’t fit. [Elektroda, Miranda Yip, post #21657695]
Is manual Gerber merging realistic for a hobbyist?
It’s possible but advanced. You must offset each file, add step‑and‑repeat codes, remove end‑of‑file markers except the last, and correctly merge drill files. The poster advises it’s “do‑able but tricky,” which reflects the risk of fabrication errors. [Elektroda, Danny Carr, post #21657694]
Do any pooled services handle panelizing for me?
Yes. One post mentions batchpcb as a pooled service that combines orders from many people into a shared panel. This can reduce cost when you don’t need dedicated panels or when multi‑design rules are restrictive. [Elektroda, Gary Crowell, post #21657693]
Will Advanced Circuits accept my self‑panelized Gerbers?
The thread doesn’t confirm their policy. However, it warns that low‑cost “special offer” deals usually won’t allow panelization. Check with your specific service tier before sending panelized files. [Elektroda, Joe Wolin, post #21657691]
Are there online tools that panelize for free?
A participant reports using online sites that do free panelizing, with acceptable results, but no URLs were provided. Consider this anecdotal, and verify capabilities and DRC/DFM checks before ordering. [Elektroda, elle Jimenez, post #21657698]
What does “panelization” mean in PCB manufacturing?
In context, panelization arranges multiple board images—often a step‑and‑repeat of a single design—onto a larger manufacturing panel to streamline fabrication. Some fabs restrict this to identical designs and impose limits like no electrical test. [Elektroda, Gary Crowell, post #21657693]
Any caveats when asking a fab to panelize multiple designs?
Expect varying policies and possible fees. One poster cites a shop that will do it but charges extra, sometimes approaching the cost of separate orders. Also watch for restrictions such as rectangular‑only outlines. [Elektroda, Gary Crowell, post #21657693]
