Manual preparation of manufacturing files remains one of the most common sources of delay and cost overruns for PCB designers. After finishing layout and passing DRC, engineers still need to generate Gerbers, drill files, BOM, and pick-and-place data, package them correctly, upload to a fabricator's website, and re-enter board parameters. A missing layer, incorrect drill format, or mismatched stack-up often triggers a back-and-forth with the manufacturer and can push a prototype out by days.
A manufacturing-oriented KiCad plugin closes this gap. It reads the finished board, produces the required files in the correct formats, and hands the design directly to the fabricator for quotation. The AIVON KiCad plugin follows this pattern, allowing designers to move from a completed PCB Editor project to an AIVON quotation with far fewer manual steps. This article walks through installation, daily use, and the engineering reasons a plugin workflow is preferable to traditional Gerber upload.
How to Install AIVON KiCad Plugin Step by Step
KiCad's Plugin and Content Manager (PCM) is the standard, supported method for installing third-party plugins. The process is the same across recent KiCad versions and keeps plugins isolated from the core application.
Open KiCad Plugin Manager
Launch the main KiCad project manager window. From the top menu choose Tools → Plugin and Content Manager, or click the Plugin and Content Manager button near the bottom of the window. An internet connection is required so the manager can reach the repository list.
Search and Install AIVON Plugin
In the PCM dialog, switch to the Plugins tab (or Fabrication / Manufacturing category if available). Type "AIVON" in the search/filter field. Select the AIVON plugin entry, click Install, then switch to the Pending tab and click Apply Pending Changes. KiCad downloads and installs the package.
If the plugin is distributed via a private or manufacturer repository, add the repository URL first via the Manage button before searching. After installation, close and reopen the PCB Editor (or restart KiCad) so the new toolbar icon appears.
Common mistakes:
- Installing but forgetting to apply pending changes.
- Looking for the icon in the Schematic Editor instead of the PCB Editor.
- Running an outdated KiCad version that cannot load the plugin's Python or IPC requirements.
Activate the Plugin
Open any PCB project and switch to the PCB Editor (pcbnew). The AIVON icon should appear on the top toolbar or under Tools → External Plugins. If it is missing, use Tools → External Plugins → Refresh Plugins. On some platforms you may also need to enable the KiCad API or plugin system under Preferences → Plugins.
Connect AIVON Account
Click the plugin icon for the first time. A login or authorization dialog opens (usually in a browser window). Sign in with your existing AIVON account or create one. Once authorized, the plugin stores the session so subsequent uses do not require re-authentication. This link allows the plugin to upload design data and retrieve real-time pricing from AIVON's system.
How to Use AIVON Plugin to Get PCB Quotes
The plugin is intended to be used only after the design is ready for fabrication. Treat the sequence as the final stage of the standard engineering flow:
KiCad Design → Design Rule Check (DRC) → Generate Manufacturing Files (via plugin) → Quotation → DFM Review → PCB Manufacturing / Assembly.
Open PCB Project
Open the project whose board you intend to order. Run a full DRC and resolve all errors and warnings that affect manufacturability (clearance, annular ring, drill-to-copper, etc.). Zone fills should be complete and the board outline clean. The plugin will export whatever is currently in the PCB Editor; incomplete or violated designs simply produce unusable files.
Launch Plugin
In the PCB Editor click the AIVON toolbar icon or select it from Tools → External Plugins. The plugin starts its export sequence.
Upload Design Information
The plugin automatically extracts board dimensions, layer count, and other physical parameters from the design. It then generates the manufacturing package (Gerber layers, NC drill, optional netlist) in formats accepted by AIVON and uploads them. You normally do not need to open the Plot or Drill dialogs yourself.
Configure Manufacturing Requirements
A dialog or browser page appears showing the detected parameters. Confirm or adjust:
- Quantity
- Material / stack-up (FR-4, impedance-controlled, flex, etc.)
- Solder-mask and silkscreen colors
- Surface finish (HASL, ENIG, etc.)
- Board thickness and copper weight
- Any special requirements (controlled impedance, HDI, etc.)
For assembly orders the same interface typically accepts or generates BOM and pick-and-place data.
Generate Quotation
Click the quote or "Add to Cart" action. AIVON returns pricing based on the uploaded files and the options you selected. Review the quotation, then proceed to order if the numbers and lead time are acceptable. Because the files were generated by the plugin, the chance of missing layers or incorrect drill formats is greatly reduced.
Why Use a PCB Manufacturing Plugin Instead of Manual Gerber Upload?
Manual export remains fully supported, but a dedicated plugin removes several error-prone steps that professional engineers encounter repeatedly.
Reduce file preparation steps Instead of opening Plot, selecting every layer, setting Gerber options, generating drills, exporting BOM and position files, and zipping the set, the plugin performs the entire sequence with manufacturer-tuned defaults. This saves time on every revision and eliminates the need to keep a personal checklist of export settings.
Avoid missing manufacturing files Common failures include omitting the board outline, using the wrong drill units, forgetting the solder-paste layer for stencil, or submitting an incomplete BOM. The plugin packages a consistent, complete set that matches AIVON's acceptance criteria, lowering the probability of an engineering query or hold.
Faster quotation process Because the design data and parameters travel together, the quotation can be generated immediately or within the normal review window (AIVON typically provides a detailed assembly quote within 1–2 working days after file review). Designers can iterate on cost drivers (layer count, finish, quantity) without leaving the KiCad environment or re-uploading archives.
From a manufacturing perspective, the plugin also encourages earlier DFM awareness. Designers see real pricing and capability feedback while the board is still open, rather than discovering issues only after a formal quote request.
FAQ
Q1: Is AIVON KiCad Plugin free?
A1: The plugin itself is free to install and use through the KiCad Plugin and Content Manager. You pay only for the PCB fabrication or assembly services ordered through AIVON.
Q2: Which KiCad versions are supported?
A2: The plugin targets current stable KiCad releases that include the modern Plugin and Content Manager and the required Python/IPC interfaces (typically KiCad 6 and later; confirm the exact list in the plugin's PCM description). Always use a recent KiCad version for best compatibility and security updates.
Q3: Can I modify my PCB after quotation?
A3: Yes. After receiving a quotation you can revise the design in KiCad, re-run DRC, and launch the plugin again. The new upload creates a fresh quotation or revision. Existing orders that have already entered production cannot be changed without contacting AIVON support.
Q4: Does the plugin replace manual Gerber generation completely?
A4: For ordering from AIVON it can. Many engineers still keep a manual export workflow as a backup or for sending files to other fabricators. The plugin is an acceleration layer, not a replacement for understanding Gerber, drill, and assembly data formats.
Q5: What happens if DRC is not clean before launching the plugin?
A5: The plugin will still export the current state of the board. Manufacturing will then either reject the files or raise DFM issues. Always clear DRC (and preferably perform a visual manufacturing review) before requesting a quotation.
