That is an interesting behavior especially with just one layer. Could you please try the following and see if it exports correctly:
first - copy/paste the bottom polygon to another PCB, and in the original PCB, delete the polygon from the bottom layer, export Gerber and see if it shows as one layer
second- go back to PCB, copy the polygon back to the bottom layer, but this time Unpour the bottom polygon and export and see if it exports as one or 3 layers.
Territory Technical Manager, SOLIDWORKS PCB
Good Morning Injy Gadalla,
Let me just start by saying thank you for taking the time to help and it is greatly appreciated. So i tried both ideas and this is what happened. When i copy the polygon pours to a new blank board it works as i would expect it too and creates only one layer. But when i turn off the polygon pours it has no affect on the change to the bottom layers outputs. This leads me to believe it is not in the polygon pours. Also another thing i found, when i added some text strings to the bottom layer (forgot to label my board), it show them with the outline of the polygon pour layer instead of with my traces and pads on the 3 layer split from the bottom layer. Not sure what is causing this separation, any more ideas that could spark ideas?
With warm regard & appreciation,
Thank you for your kind words . I am here to help!
Without examining the PCB file it's really hard to tell what might went wrong . May be the bottom layer got corrupted ? Can you try adding another layer copy all the content from the bottom to the new layer and generate gerber to see if it the new layer exhibits the same behavior as the bottom . We can also start with process of elimination , delete all the objects from bottom and see if it still generate 3 layers ? If not , then add half of the bottom layer objects and see if the issue occurs . We try to see if we can narrow it down to an object or the layer somehow got corrupted.
You can always submit a support ticket through your VAR and let me know and I can internally track it down.
Good Afternoon Injy Gadalla,
So after some deep research, It was found that my font choice was causing the separation of the top layer. Not sure how or way it would affect the top layer and not just the legend (silk screen layer) but my next step is to figure out what font is safe. Then again it could all be just a glitch, not sure what will avoid this issue just yet. I will update this post with my findings after more work has been created, very new to this software as well as board layout and design. I do thank you for all the assistance with trying to help me with this anomaly.