How to generate Gerber files from KiCAD

Update in 2017: New Version of KiCAD (version ≥4.0.0) has improved gerber format compatibility. If you use old KiCAD, please update your kicad for better performance. Here is the configuration for New KiCAD.

Here is a old version for Kicad Guide line.
Thanks so much for our Friend Ches, this article was written by him in 2013. The content is very detail even a green hands can generate a Gerber file according to it. Thanks again for Ches's sharing.
Original article:

Seeedstudio Fusion is a batch PCB service for 2- and 4-layer boards. With shipping, the cheapest option is ten boards, 5x5 cm (2x2 inch) maximum size, for $15. The turn-around time is just about a month, which includes about a week to build and about three to ship. The quality is high enough, and the DRC rule limitations are acceptable, for hobbyist work.
Their instructions are not entirely clear for KiCAD. Here's how I got started, and received boards precisely as I expected.
Let's get the basics out of the way.
  1. Learn KiCAD
  2. Create a schematic
  3. Create a board layout
  4. Pass DRC with Seeedstudio Fusion's rules
  5. Learn how to generate gerbers and a drill file
At this point, the real challenge is to figure out how to generate the proper gerbers. Why is this an issue? Well, if we look at Seeedstudio's requirements (as of writing this article):
Gerber file requirements:
The following layers are needed:
  • Top Layer: pcbname.GTL
  • Bottom Layer: pcbname.GBL
  • Solder Mask Top: pcbname.GTS
  • Solder Mask Bottom: pcbname.GBS
  • Silk Top: pcbname.GTO
  • Silk Bottom: pcbname.GBO
  • Drill Drawing: pcbname.TXT
  • Board Outline?pcbname.GML/GKO

The Gerber file must be RS-274x format.
Now when you open up your Plot dialog, you should check the B. SilkS (back/bottom silkscreen), F. SilkS (front/top silkscreen), and Edge.Cuts(outline) gerber options. Your screen should look something like this:
Plot Dialog
And in the drill file screen, you should check Minimal Header box, and select Suppress Leading Zeroes from the 'Zeroes Format' selection, leading to a 2:4 precision. It should look like this:
Drill Dialog
Now click the Drill File button, close the drill dialog, hit the Plot button, and close that dialog as well.
Check your gerbers in gerbviewer (gerbv) to make sure everything is right. In the example below, I made sure that the vias looked right, the drills looked right, the stop-soldermask looked right on the top and bottom, the silkscreen looked right on the top and bottom, the copper looked right on the top and bottom, and that the dimensions looked right. A lot of checking! (And I still missed one small thing, which thankfully turned out to be a gerbv bug and not my mistake.)
Here's what mine looked like for a recent project (front and back, respectively):
Gerber Front Gerber Back
Ches Koblents
October 13, 2013

Fusion Technical Support

  1. What is Gerber file?
  2. What are the PCB panelization rules?
  3. How to generate the Gerber (manufacturing) files?
  4. What is the correct way to draw the silkscreen on the bottom side?
  5. My PCB does not require Solder Mask, what should I do?
  6. My PCB does not require Drill Holes, what should i do ?
  7. Which layer should I use in EAGLE for milling?
  8. What is the depth and width of the v-cuts/grooves?
  9. I don't want silkscreen on my PCBs, how can I proceed with a PCB Assembly order?
  10. What are the dimensions for Dielectric Separation thickness?
  11. What is the thickness of the inner copper layers?
  12. What are Blind and Buried Vias?
  13. What is the The Min Track/Spacing for 1oz./2oz./3oz. Copper weight
  14. What are Plated Half-Holes/Castellated Holes?
  15. How do I design non-plated through holes?
  16. What PCB materials are available in Seeed Fusion?
  17. What is the thickness of Fusion PCB?
  18. What PCB surface finishes are offered in Seeed Fusion?
  19. What color options are available for the solder mask/resist?
  20. What is the PCB copper weight?
  21. What is Impedance Control?
  22. PCB quantity
  23. How to generate Gerber files from PCBE
  24. How to generate Gerber files from Eagle
  25. How to generate Gerber files in Altium Designer
  26. How to generate Gerber files from CircuitMaker
  27. How to generate Gerber files from KiCAD
  28. How to generate Gerber files from DipTrace
  29. How to generate Gerber files from Proteus
  30. How to generate Gerber files from DesignSpark
  31. How to convert drilling layer from Gerber to Excellon format in CAM350
  32. Recommend size for BGA
  33. Solder Mask Dam
  34. What is the difference between Fusion standard PCB and Fusion Advanced PCB?
  35. What should i do when my Gerber files over too big (over 4MB)?

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