PCBexpress Capabilities:

• 2-6 layers up to 100pc.
• Industry standard 0.062" FR-4 laminate.
• Standard 1oz. finished copper weight.
• Minimum trace & space to guarantee manufacturability .006
• Routed to customer provided outline (see details)
• Smallest board dimension .35 inch in one direction. Smallest square board = .64 x .64.
• Maximum board size is 12 x 14 (to 168 sq-inches)
• Tin lead finish
• 24 drill sizes available (finished size after plating):.008, .016, .020, .025, .029, .033, .036, .040, .043, .046, .053, .061, .067, .080, .087, .093, .100, .110, .125, .141, .151, .167, .193, .251 (.008 available with 4 and 6 layer only)
• Green soldermask over bare copper (SMOBC)
• 1 or 2 sided silkscreen (also known as “legend” or “nomenclature”).

Convert to Gerber File Conversion Service:
This service has moved to our Full Featured Sunstone Website Click here for details.

2012 HOLIDAYS OBSERVED:

Holiday Schedule

Required Files:

Depending on the CAD program you use and the type of PCB you need, the file quantity will vary from 3-11 files. Layers must be viewed in Viewmate as a single layer. We cannot merge layers to create a single layer. All component and solder layer gerber files are plotted as positive as viewed on the screen.

Please see our Preview Tips for more information for previewing your files using a gerber viewer.

PCBexpress #1 & PCBexpress #2 are 2 layer circuit boards and require:

• 2 Positive Gerber layers: Top & Bottom
• Aperture/Dcode file (if not RS274X)
• NC Excellon Drill file
• Drill Tool list
• Silkscreen (only available on Express #2)
• Soldermask Top & Bottom (only available on Express #2)

MLBexpress #4 are 4-layer circuit boards and require:

• 2 Gerber outer layers: Top: Positive, Bottom: Positive
• 1-2 inner layers: plot based on setup
• Aperture/Dcode file (if not RS274X)
• NC Excellon Drill file
• Drill Tool list (if not embedded within NC Drill file)
• Silkscreen
• Soldermask Top & Bottom

MLBexpress #6 are 6-layer circuit boards and require:

• 2 Gerber outer layers: Top: Positive, Bottom: Positive
• 3-4 inner layers: plot based on setup
• Aperture/Dcode file (if not RS274X)
• NC Excellon Drill file
• Drill Tool list (if not embedded within NC Drill file)
• Silkscreen
• Soldermask Top & Bottom

Orders will be run as sent using our standard manufacturing process.Any additional files in the zip file will be ignored. Read me, design document, and drawing files will be ignored.

If your needs go beyond our product or material specs please quote using our PCBpro Web site.

You may name your files what you like, we just need to know what they are named. You will be prompted to list them on the order form.

• Please keep layer names short.
• Our order form only requires your file extension name.
• All files need to be in a single zip file.
• You will be prompted to upload files at the end of the order process.

NC Drill File Requirements:

See Preset Drill Sizes
See Recommended Pad & Clearances

NC Drill File: The NC Drill file defines hole locations and tool numbers (X&Y coordinates).
All holes are plated through meaning there will be solder in the hole barrel.
We cannot guarantee Non-Plated through holes.

• Preferred format is 2.4 non-metric.
• Drill file must be ASCII text viewable.
• PLEASE CHECK THE DRILL FILE IS NOT A DRILL IMAGE OR FAB DRAWING! Example
• Do not send a "program" drill file: Example
• Please view your NC drill file in notepad or word pad to verify it is ASCII text.
  Drill file should not contain “G01, G54”, or "D" (this indicates a gerber format) code references when opened in Notepad.
  Most have "T" codes separating tool sizes (T1, T2, T3).
• Typical drill file examples: Example A or Example B

Restrictions:

• All holes are through hole from top to bottom layer of board.
• No Blind or buried vias.
• No connected holes, slots, canned circles. Please make sure there is space between holes, we require .010 from object edge to edge. If holes touch small holes <.059 could be deleted, holes >.059 could continue drilling and cause mis-shapen holes.
• Please limit your total number of holes per board design to no more than 35 per sq-inch.
  
  For example; if the total area of the circuit board is 9 sq-in, there is a limit to 315 max holes per board. For designs exceeding 35 holes per sq-inch there may be an added surcharge of 10% of board cost.

Drill Tool Sizes:

Drill Chart in Inches & Recommended Pads/Clearance Sizes in Inches:
Note: .008 via has a finished tolerance of +.006/-.008 and not guaranteed to plug.
(.008 size only available for 4-6 layer orders.) All other hole sizes finish within +/- .004

Precise board perimeter routing; most board shapes allowed:

Details: PCBexpress programs the board routing specification automatically by reading the path of your outline. Outline must be a continuous line; round or odd shapes ok when following our guidelines although, the shape should be very simple to be considered for the PCBexpress quick-turn service.

Our overall board dimensions are calculated from the center of the traces used to draw your board outline.

You should leave a .020 space from the fab edge of the board to the nearest copper elements to prevent traces from being cut off and possible mask peeling and exposed copper.

Due to the simplicity of our service, please check your outline for compatibility prior to submitting your files so there are no disappointments. See our "TIPS" below for checking outline.

Restrictions:

	Limit to 1 pass of outside board perimeter using .093 router bit; no internal cutouts.
	No internal cutouts, tab routed (array) pallets, v-score or slots for PCBexpress services -- Please try PCBpro.
	Connected or Panelized boards are not cut apart, you will need to cut smaller boards from main panel. We recommend a Dremel tool, rotary cutter or small saw for separation. A continuous outline must be placed around individual boards connected with tabs; channel widths between boards must measure no less than .110 between boards otherwise a default square/rectangle may be placed unless you specify to hold for outline redraw. See Sample Picture
	Break away or Perforation Holes: Due to popular demand we have removed the Perforation/Break-away Holes restriction previously stated. Please limit your total number of holes per board design to no more than 35 per square inch. For example; if the total area of the circuit board is 9 sq-in, there is a limit to 315 max holes per board. For designs exceeding 35 holes per sq-inch there may be an added surcharge of 10%
	Inside Chamfer not recommended (an inside cut made usually at a 45° angle to the adjacent edges). See example

Answers to common 2-6 Layer Inquiries:
What is the thickness and construction for multi-layer boards?

• 4-6 Layers: Limited to 14" in X or Y
• Our standard construction builds .062 +/- .007.
  We begin with a .028 mil core (.028 mils of laminate with 1 oz of copper laminated to each side. This will be layers 2 and 3 (the middle two). We print the design for the inner layers on each side then etch. We then laminate .012 mils of fiberglass (also known as "glass", "pre-preg" or "dielectric") to each side and a sheet of half ounce copper foil on each side.
  
  Our standard multi-layer construction looks like this:

Material Specs:

• We use a variety of laminate material suppliers including Nanya and Isola.
• We are unable to test for controlled impedance. (Our Full Service and PCBpro Design check can build to set specifications but we have no way of determining what they should be or are).
• Currently we do not use teflon, high frequency, or flexible materials. We may offer other material types in the future.
• If you have a special construction need outside our standard construction please quote using our PCBpro service at www.PCBpro.com

What is my board size limit?

Your design is setup on a panel with other customer orders to run in the process batch.
The smallest board size is 0.35" (X or Y) for these services.
The largest board size allowed is 12 x 14 inches for all 2-6 layer services.
If your board requires larger panelization beyond these limits please try our PCBpro site: www.PCBpro.com

Can I order more than the PCBexpress lot size allows?

You may quote higher quantity or other lead time pricing on our quote form: www.PCBpro.com

What about v-score or tab routing?

PCBexpress does not offer v-score or tab routing.
Please use our quote form on www.PCBpro.com

Can I order 2-oz copper instead of standard 1-oz?

PCBexpress uses 1-oz finish copper weight. Other copper weights are featured on our enhanced services located at: www.PCBpro.com

Can I have text without silk-screen?

Any text on a gerber layer will be etched in copper. Many designers use this technique on the Express #1 service if they do not need the silk-screen or soldermask. Keep in mind the minimum trace width is .007 or it may not appear on the board once etched. Our CAM department will not make corrections to text/trace size, all orders are run as sent.

Can I have surface mounts?

Surface mounts are not a problem for PCBexpress orders and no extra cost to produce boards with surface mount pads. We will run your files as sent.

• Please read the order set-up information including the Pre-order File Checklist.
• Choose one of the services from our Product Menu (above).
• All pricing and order form links are located for each service type.
• Click the order button for the service that fits your needs.
• Fill out and submit the appropriate order form.
• You will see a confirmation page with an order number.
• You can click to print the order confirmation on the screen.
• You will receive an immediate email confirmation you successfully placed your order.
• Your order will ship according to the projected lead-time schedule (below).
• You may check your order using our online tracking system.

What payment options are acceptable?

Credit card payment is the most convenient and preferred option. Master Card, Visa, American Express, and Discover Card are accepted, we do not accept Diners Club.

Other Payment Methods:

• COD accepted, make check payable to: PCBexpress c/o Sunstone Circuits
• PCBexpress™ Credit Account Requirements:
  minimum 3 consecutive months of usage with a minimum purchase amount of $300.00 per month. Please contact our credit department if you meet these requirements and desire consideration for application and credit terms.
• We cannot ship from open Purchase Orders without Sunstone Circuits credit account information. (PCBexpress is a division of Sunstone Circuits, Inc.)
• Wire Transfer payment for International orders will not be accepted.

How do I reorder a previous job?

You will need to know your part number or old order number to reorder.
1. Go through the order form to place a new order
2. for the layer names you may list your old order number (or part number)
3. Click "continue to next page"
4. The next page will ask you to upload or choose a previous order file.
5. Choose your old order file; click continue
6. Our system will pull the info so you do not need to send any files.

Where should I send my files?

An automated file browser window will appear upon completing your order to attach your file to your order, or you may follow the instructions in your order confirmation to send your files.

You will be notified via hold email if your file is missing, you will be instructed to reply & attach your file(s) to the email to send it to our CAM department.

The order form does not work!

It is advised to keep your Internet browser updated with the latest bells & whistles. Your internet browser preferences must operate using "cookies enabled" & active Java script.

A common situation is a lost internet connection or time-out on the secure credit card submission page. We recommend a fresh connection to the internet and also hit the refresh button when at the site it is possible your browser has not updated the pages.

Some companies and schools use special security settings to prevent Java enhanced sites from being executable, check with your I.T. person to find the problem.

If your file is too large using the upload feature, the site will time-out and null your order. You will need to place your order again and email your file.

How will I know my order is being processed?

All orders are processed in the order they are received. You may always check your order using our online Order Tracking System. (Status is updated at various times through-out the day and shipping info is automatically uploaded after 5pm (PST).

A Hold Status will be sent if there is a problem indicating your file problem.

We cannot call customers with error problems. PCBexpress™ is an online service. A description of the problem and/or a screen print is sent hi-lighting the problem via email. Problem orders are held until the next process day, or until the problem is resolved or correspondence with the customer has taken place.

You will get a shipping notification via email when your order ships.

Did you receive my files or order form?

If you have entered a valid email address, you will receive an immediate email order confirmation when your order is received within our Pre-Engineering dept.

You may always check your order using our online Order Tracking System.
Manufacturing status is updated at various times through-out the day; shipping info is available after 5pm (PST).

Why would my order be held up?

PCBexpress™ is not responsible to correct, revise or second guess a designer's files. It is advised you examine ALL of your files - we will build exactly what we receive per your order form and files.

A "problem order" will be set aside until all of the order files for the day have been processed to give them all "equal time" before referring back to the incomplete or problem orders. If there is a problem you will be notified via email so your order can be fixed in time for the next process day.

Orders WILL be immediately put on hold if it does not fit the criteria as outlined within the technical guidelines or if files are missing data.

Preview your design files before ordering - see "Preview tips"
To prevent delays or common design problems - see our Pre-Order Check List

What causes a order to go on HOLD?
What causes problem boards?

Shipping Info

Please check the lead-time projection schedule for estimated ship date.

Combine multiple shipments and/or changing delivery method or address:

All orders are packaged upon completion though, we are happy to change your shipping so it is most convenient to you with the following set guidelines:

1.) Combined orders must be already scheduled to ship on the same date.

2.) Your request MUST reach (email or phone) Customer Service no later than 9-am on the scheduled ship date.

Note: Changes cannot be made after 9-am (PT) on the scheduled ship date.

3.) Please email your shipping change request immediately after placing your order(s). Include your order number(s) when contacting Customer Service.

If requested, we will do our best to combine your multiple orders into the same package to help save shipping costs. We are happy to change your shipping method to be most convenient for you.

Can I Expedite my order to have it faster?

Yes! We do offer an Expedite service on a case by case basis for E2, E4 & E6 services . You can eliminate 1 day of lead-time to have your order when you need it (some restrictions do apply). There is a 50% Expedite Fee added to the board cost.

After placing your PCBexpress order please call our Customer Service desk to make arrangements.

Note: There is a checkbox on our order forms to automate your request if your order qualifies for an Expedite Upgrade.

Multi-Layer Inner Layer Tips:

Please double-check pad and/or clearance sizes for all holes are sufficient to the finish drill sizes. PCBexpress is not responsible for copper pads or clearances used that are less than our recommended sizes.

Ground Layers: All Pads with thermal inner layers will be plotted default as negative, the pads/thermals will be clearances while the surface area will flood with copper.

For ground layers require clearances .035+ larger than finish hole size to ensure no shorting on inner layers. Please refer to the finished drill sizes for recommended clearance sizes for our preset drills. The cheat sheet link on that page will show you how our automated programming places any non-standard drill sizes into our preset finish sizes using the tool range.

If most of your inner layers are ground plane: The easiest method is to "flash" the pads then draw .050 mil trace back set/keep-out areas for processing. (See sample picture A.) This results in a negative plot where our film will flood the empty area with copper. The pads, backseats& keep out areas will be clear of copper. (See sample picture B.)

Drawn Layers: All drawn inner layers (often referred as signal layers) will be plotted positive, only the drawn areas will be copper. To achieve a positive ground plane: Draw with an .008 trace using a .002 overlap. This gives a solid appearance. (This works for the outer layer files as well.)

Questionable files will be held for clarification.

If you are building a 3-layer board it is advised do NOT send the layer file to be omitted. Type "none" on the order form as file layer name. Add the comments to the order form "this is a 3 layer board." This will assure you will get what you expect.

Our plotter system is able to output most complicated images.

Preview your files:

A visual check should be done after the Gerber files are generated.

VIEWING FILES: The best benefit to you as the customer is knowing how the Gerber files look once we receive them.

Checking your design in a gerber viewer is very crucial. With a viewer, you will see what we see. Below are some simple things to look for when previewing your files:

When using a viewer, you will not be able to import from a zip file so you must have all the files in a folder on your computer.

Check gerber layer orientation:

This is an important step from within the viewer.

To check gerber apertures/d-codes:

1. Make sure there are sizes, locations and shapes, there should be no "?" showing in the fields.
2. Check there are no apertures sizes larger than 1"
3. Text sizes need to be .007 or larger. Less than .007 will be etched away, silk-screen too small will be illegible.
4. Look for "M" shapes, these need to be modified in your list as standard shapes, our plotter system may not recognize the shape or our CAD program default output may interpret to an unexpected shape.

To check Drill Tool Size:

1. Tools should have sizes, include tool list if they do not auto load into the viewer.
2. Drill files need to be a single layer file, if not merge into a single file prior to submitting.

How to check board outline:

1. Import the gerber layer that has the outline.
2. Click on any place on the outline, if the entire outline is not’t highlighted, or only highlighted in a small area, it is not connected. Continue clicking around the perimeter of the board several times.

Your cut line must be redrawn until it is a single continuous line when selected from any point. Our Cam Tech will use this same selection tool to grab the outline for the router program and it must be a single line and require little or no rework to function properly.

NOTE: Non-Continuous/Odd or Difficult Shapes: We reserve the right to change the board shape to a default 0.0 square or rectangle snapped to the existing board outline IF the board shape is difficult or not a continuous line. No Hold or Alert notice will be sent unless you specified on order form to hold the order.

Alternately, you have the option to specify on the order form comments: "Hold if outline is difficult" where we will hold your order for you to redraw the outline to be a continuous non-breaking line.

Odd or difficult shapes are defined as broken lines, overlapping lines, and/or improperly drawn arcs.

Missing Outline: If outline is not present on the layer specified on your order form your design is processed as sent. We will create a square/rectangle outline .020 from the nearest copper feature if outline is missing. No Hold or Alert notice will be sent unless you specified on order form "hold the order for outline redraw."

Misc. Cad Program Tips:

Eagle HELP for PCBexpress:

Design Note: Always use Vector Fonts! The Eagle Cam processor will automatically output as vector font, other fonts used could cause text to expand.

Eagle font fix: Open Eagle, on the menu bar choose Options/User Interface and select the option "ALWAYS VECTOR FONT". Problems may exist if the user is using a different text font. Using the Vector Font only will allow you to see exactly what you are going to get. See Vector.gif

(disclaimer: PCBexpress is automated without design review, orders will be processed as sent without notification of font related issues).

Custom Eagle Cam Scripts - Convert to Gerber the Sunstone way!

Download our preset Eagle Cam jobs to convert your own Eagle files.
Each Cam job is customized for any of our Sunstone pcb services, your files will be renamed for easy layer identity. Easy step by step instructions are included within the zip file.

CAM Download
Step by Step Eagle File Conversion Instructions

IVEX: Please note Ivex has gone out of business so we recommend customers try our No Cost design software PCB123 since we can support it here.

Ivex files are mirrored by default when created. It is advised to place "right reading" text somewhere on the top layer and name the file extensions names *.L1, *.L2 etc. for proper orientation. If there is no text on the layers, they will be run "as-sent".

PADS:

To create single gerber layer files (files that do not expand into multiple layers) in the PADS software Un-check the fill and macro boxes in the advanced gerber setup.
See PADS_fix.gif

Orcad:

Here is what you need to do to get Extended Gerber files from OrCAD Layout:

1. Open the .max file in Layout
2. Select Options->Post Process Settings…
3. Click in the header box labeled "Device" so that the entire column is highlighted
4. Right-click and choose "Properties..." from the pop-up menu
5. Set the Output Format to "Extended Gerber" and click OK
6. Right-click inside the Post Process window and choose "Run Batch" from the pop-up menu to generate a new set of gerber artwork files in the RS-274X format.

There are many good tips regarding post processing (generating gerber/drill files) can be found here; Click the link and do a search for "Post Process"

Do you accept Auto-Cad (DXF) files?

We cannot accept Auto-Cad (DXF) files. We do not have a software to convert the format. Once your files have been converted to gerber and Excellon formats, we would be happy to accept them for processing.

I don't have computer files of my design.

We recommend a scanning company to convert your drawings to gerber images and Excellon drill files. We recommend Artnetpro.com for a good scanning and design source.

You may also check our links page for recommended designers who are familiar with our format. Try PCB123.com for our free pcb design software!