The Gerber problems that most often stall a quote or build are a missing board-outline layer, zero solder-mask clearance, drill-file unit mismatches, omitted aperture macros, and silkscreen crossing into pads.
- Missing board outline layer — fab shops cannot quote or produce without it
- Solder mask clearance set to zero — all pads will be covered
- Drill file units mismatch (metric vs. imperial) — verify with your EDA export settings
- Aperture macros not included — some older Gerber viewers/importers require explicit aperture definitions
- Silkscreen artwork crossing into pads — causes inspection issues and may short
- Multiple board outlines in separate files — consolidate all outlines in one layer