How to generate Gerber file 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 Gerber file
  4. How to export the drill files correctly?
  5. What is the correct way to draw the silkscreen on the bottom side?
  6. If my PCB does not require Solder Mask, what should I do?
  7. If my PCB do not require Drilling Holes, what should i do ?
  8. Which layer should I use in EAGLE for milling?
  9. What is the depth of the v- cut?
  10. If my PCB's do not have the silkscreen, how can I proceed with my PCBA order?
  11. Exporting manufacturing files from Altium Designer
  12. Export PCB gerber from Cam
  13. How to export the correct drilling layer from eagle
  14. What is the minimum trace width?
  15. What are the dimensions for Dielectric Separation thickness?
  16. What is the inner layer copper thickness?
  17. What is the range for the drilling hole diameter?
  18. What is Blind/Buried Via?
  19. What is the The Min Track/Spacing for 1oz./2oz./3oz. Copper weight
  20. How to output drill file correctly ?
  21. Is the board outline could only be rectangle ?
  22. What is the layer?
  23. What is Half-cut/Castellated Holes.
  24. How can i do if i do not required to make plated through holes?
  25. Options of Fiducial
  26. What is the size of the Fiducial?
  27. The dimension for PCB
  28. How do plated through slots work on the Gerber ?
  29. The material for FR-4/Aluminum Board/FPC
  30. The thickness of PCB
  31. The surface finish for PCB
  32. The color of solder mask
  33. The copper weight for PCB
  34. What is Impedance Control?
  35. PCB quantity
  36. How to generate Gerber files from PCBE
  37. How to generate Gerber file from Eagle
  38. How to generate Gerber files in Altium Designer
  39. How to generate Gerber file from KiCAD
  40. How to generate Gerber files in DipTrace
  41. How to generate Gerber files from Proteus
  42. How to generate Gerber files from DesignSpark
  43. Recommend size for BGA
  44. Solder Mask Dam
  45. Difference between standard PCB and Advanced PCB

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