If you were just going to attempt to convert either DXF example above to Gerber it would result in outlines only (no boundaries detected or filled). For example a donut in a DXF file should be two circles with something to indicate the inner circle will be clear Solidworks will just export 4 arcs total without any indication the interior circle should be clear (see below). Solidworks exports their DXF as individual lines/arcs which are not continuous (required to form a closed boundary when performing file conversions).
Gerber Rule #2: Each boundary must be defined as either Dark or Clear (i.e Paint/Scratch). For example a square in a DXF file should be a single closed 0-width polyline Solidworks will export their DXF as 4 individual line entities (see below). Gerber Rule #1: All boundaries must be closed and continuous. Lets quickly review both Gerber rule violations of the SOLIDWORKS DXF and then provide a solution.
Unfortunately the DXF files generated from SOLIDWORKS violate both of these rules, and have caused conversion nightmares for almost all SOLIDWORKS users who wished to quickly generate Gerbers from their 3D layout designs.
All boundaries must be closed and continuous.The Gerber format is very old and stubborn (first released in 1980), and has it's own set of rules which must be followed to ensure a successful conversion from DXF. Note: This article is relevant for SOLIDWORKS and all other 3D modeling software tools (such as Inventor, Sketchup, Rhino, AutoCAD, ProEngineer, etc.). DXF is the most popular CAD format in the world, so it would make sense to simply export a DXF from SOLIDWORKS and convert it to Gerber - What could go wrong? Many SOLIDWORKS engineers have a requirement to convert their 3D layout design to Gerber for manufacturing of PCB.
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