Most engineers still follow a multi-step process after finishing a KiCad design: export Gerbers, generate drills, prepare BOM and pick-and-place files, zip everything, upload to a manufacturer website, manually enter board parameters, wait for DFM feedback, and correct any issues. Each hand-off introduces delay and the risk of missing layers or mismatched settings.
A more efficient path now exists. With the right plugin, you can move from a completed KiCad project to a manufacturing order while staying inside the design environment. This article compares the traditional workflow with the integrated approach, walks through the exact steps, lists the files manufacturers still require, and shows how the process reduces common errors.
Traditional KiCad-to-PCB Manufacturing Process
In the classic flow an engineer must:
- Finish the layout and pass DRC
- Export Gerber files for every copper, mask, silkscreen, paste, and outline layer
- Generate Excellon drill files with matching origin and units
- Create a BOM and pick-and-place (centroid) file if assembly is needed
- Package the files into a ZIP archive
- Upload the archive to a manufacturer portal
- Manually enter board dimensions, layer count, thickness, surface finish, quantity, and other options
- Wait for the manufacturer's CAM or DFM team to review the data and request corrections if anything is incomplete or non-compliant
The process works, but it is time-consuming and error-prone. A single missing layer or inconsistent origin often results in an order hold.
The New Workflow with AIVON KiCad Plugin
The integrated workflow keeps the engineer inside KiCad for as long as possible:
- Design and verify the board in the PCB Editor
- Run Design Rule Check and resolve all critical issues
- Launch the AIVON KiCad Plugin
- Submit the design data for automatic packaging and quotation
- Review manufacturing options and any instant feedback
- Confirm and place the order
Because the plugin handles file generation and parameter extraction, the chance of uploading an incomplete or misaligned package drops significantly. Professional engineering validation still occurs, but the path from layout to order is shorter and more reliable.
Step-by-Step: From KiCad Project to PCB Order
- Complete PCB design
Finish routing, copper pours, silkscreen, and board outline. Confirm the stack-up and layer definitions in Board Setup. - Run DRC checks
Open Inspect → Design Rules Checker. Clear every error and address important warnings. Refill all zones (press B) so copper planes are up to date. - Open AIVON Plugin
From the PCB Editor, launch the AIVON KiCad Plugin (available through the Plugin and Content Manager or the toolbar once installed). The plugin reads the current board data. - Submit design
The plugin packages the necessary manufacturing information and sends it for quotation. Key parameters such as board size, layer count, and thickness are extracted automatically. - Select manufacturing options
Choose quantity, surface finish, solder-mask color, silkscreen color, and any additional services (impedance control, panelization, assembly, etc.). Review any feedback returned by the system. - Confirm order
Once the quotation is acceptable, confirm the order. The manufacturing files remain available for your records, and production proceeds under the manufacturer's standard process controls.
This sequence keeps the engineer focused on the design rather than on file logistics.
What Files Does PCB Manufacturing Need from KiCad?
Even with an automated workflow, the underlying data must still include:
- Gerber files for all copper layers, solder mask, silkscreen, paste (if required), and the board outline (Edge.Cuts)
- Drill files in Excellon format with consistent origin and units
- BOM listing every component with reference, value, footprint, and manufacturer part number when assembly is ordered
- Pick-and-place files (centroid / position files) containing X/Y coordinates, rotation, and side for automated assembly
The plugin generates or packages these files from the KiCad project so the engineer does not have to create and upload them manually. The same data quality rules still apply: zones must be filled, origins must match, and DRC must be clean.
How AIVON Simplifies PCB Manufacturing for KiCad Users
The plugin automates the repetitive packaging and parameter-entry steps that traditionally consume time and introduce mistakes. Once the design is submitted, AIVON's engineering team performs manufacturing validation—checking layer completeness, drill alignment, clearances, and process compatibility—before production begins. Feedback is returned early so any necessary corrections can still be made inside KiCad.
The result is a shorter path from finished layout to confirmed order, fewer file-related holds, and continued access to professional engineering support throughout fabrication and assembly. Engineers spend less time managing ZIP archives and more time iterating on the design itself.
Moving from a finished KiCad design to a manufacturing order no longer requires a long chain of manual exports and uploads. By completing the layout, running DRC, and using the integrated plugin workflow, engineers can obtain quotations, receive manufacturing validation, and place orders with fewer intermediate steps and lower risk of file-related delays. The complete path—from schematic to fabricated board—becomes more predictable and efficient.
FAQ
Q1: Do I still need to generate Gerber and drill files manually when using the AIVON KiCad Plugin?
A1: No. The plugin extracts and packages the required manufacturing data from your KiCad project. You should still run a full DRC and refill zones before launching the plugin so the underlying data is clean.
Q2: Can I order both bare PCBs and assembled boards through the same workflow?
A2: Yes. After the design is submitted you can select fabrication-only or fabrication-plus-assembly options, including BOM and pick-and-place data when assembly is required.
Q3: What happens if the plugin detects a potential manufacturing issue?
A3: The system or the engineering review will flag the concern. You receive feedback while the design is still open in KiCad, allowing you to correct the layout or settings before the order is finalized.
Q4: Is the traditional manual upload process still available?
A4: Yes. You can always export Gerbers, drills, BOM, and pick-and-place files yourself and upload them through the standard web portal. The plugin simply removes the manual packaging and parameter-entry steps for most projects.
Q5: How do I install the AIVON KiCad Plugin?
A5: Open KiCad's Plugin and Content Manager, search for the AIVON plugin, and install it. Once installed it appears in the PCB Editor toolbar or under the Tools / External Plugins menu, ready for use on the current board.
