CopperCAM 2026 — Complete Guide to PCB Isolation Milling, Drilling, and Cutting

What Is CopperCAM?

CopperCAM is dedicated CAM (Computer-Aided Manufacturing) software for converting PCB design files into machine instructions for CNC milling of printed circuit board prototypes. Developed by Galaad (France), it handles the complete workflow from Gerber and Excellon file import through isolation contour calculation, drill path generation, board contour cutting, and G-code output — bridging the gap between your PCB design software and your CNC machine.

CopperCAM is not a PCB design tool and it does not directly drive CNC machines. Its role is CAM: taking the geometric information from your PCB design software (KiCad, Eagle, Altium, EasyEDA) and producing the G-code (or other format) that your CNC controller software (GRBL, Mach3, LinuxCNC, bCNC) can execute.

Who uses CopperCAM:

Electronics hobbyists and makers prototyping boards at home with a desktop CNC router
University and vocational school electronics labs
Engineers who need rapid one-off or low-volume PCB prototypes without waiting for fab house turnaround
Makerspaces and hackerspaces with CNC milling capability

The core advantage over free alternatives (FlatCAM, pcb-gcode): CopperCAM handles more Gerber format variations reliably, has better support for complex pad shapes (including KiCad’s parametric macro pads since the September 2025 update), provides cleaner isolation path calculation, and offers a more polished workflow for double-sided boards. Many users report starting with FlatCAM and switching to CopperCAM after encountering import issues or poor isolation path quality.

Installation and Licensing

System requirements:

Windows 2000, XP, Vista, 7, 8, 10, or 11 (32-bit native application, works on 64-bit systems)
No special hardware requirements — runs on any modern PC

Installation: Download the installer from galaad.net. The installation is unusually clean — CopperCAM doesn’t scatter files across the system or add unnecessary registry entries. Everything stays in the installation directory; uninstalling is as simple as deleting the folder.

Trial version: CopperCAM’s trial has no time limit — you can use it indefinitely. The limitation is output: the trial restricts export to 25 drill holes and 25 isolation contours per export session. For simple test boards this is enough to evaluate the complete workflow. For extended testing on complex boards before purchasing, contact Galaad to request a time-limited full license.

License: A single perpetual license covers the full feature set with no ongoing subscription. Before purchasing, Galaad strongly recommends testing your specific CAD software’s Gerber export with the trial — Gerber format variations can cause import issues, and it’s better to discover compatibility problems before buying.

The PCB Milling Workflow

Understanding the isolation milling process is essential for using CopperCAM effectively:

What Is Isolation Milling?

Unlike traditional chemical etching (which dissolves unwanted copper with acid), isolation milling uses a CNC machine with a V-bit or straight engraving tool to mechanically remove copper from around traces and pads, leaving the copper you want intact. The tool cuts a narrow “isolation channel” between traces, isolating them electrically.

Advantages over chemical etching:

No chemicals, no mess, no disposal concerns
Results in minutes, not hours
Works with any copper-clad board material
Fully repeatable and automatable

Key challenge: The isolation path must be calculated precisely — it must remove just enough copper to create electrical isolation without cutting into the traces themselves. This is CopperCAM’s primary function.

Complete PCB Milling Workflow with CopperCAM

PCB Design Software (KiCad / Eagle / Altium)
        ↓
Export Gerber files (RS274-X) + Excellon drill file
        ↓
CopperCAM
  → Import layers
  → Align layers (auto or manual)
  → Calculate isolation contours
  → Configure tool library
  → Set drilling strategy
  → Define board contour cutout
  → Export G-code
        ↓
CNC Controller Software (GRBL / bCNC / Mach3 / LinuxCNC / Candle)
        ↓
CNC Machine mills your PCB

Step-by-Step CopperCAM Usage

Step 1 — Export Gerber and Drill Files from Your PCB Software

From KiCad:

File → Fabrication Output → Gerbers (.gbr)
Select layers: Front copper (F.Cu), Back copper (B.Cu), Edge Cuts
Under General Options: check “Use drill/place file origin”
Export format: Gerber RS274-X (strongly recommended over RS274-D)
Then: Generate Drill Files → Format: Excellon, Origin: Drill/place file origin

From Eagle:

CAM Processor → Gerber RS274-X job
Export top copper (gtl), bottom copper (gbl), drill file (drl)

Critical setting: Use RS274-X extended Gerber format — it embeds aperture definitions within the file. With older RS274-D format you’ll need to manually define aperture shapes after import, which is error-prone.

Note on KiCad parametric macros: Rounded rectangle pads in KiCad use parametric macros with variables. Versions of CopperCAM before September 2025 could not read these, causing import failures on KiCad boards with rounded pads. Update to the latest version to avoid this issue.

Step 2 — Open and Import Files in CopperCAM

Launch CopperCAM → File → Open
Select your front copper Gerber file → Assign it as “Component side” (top)
File → Open Additional Layer → Select back copper Gerber → Assign as “Solder side” (bottom)
File → Open Additional Layer → Select Edge Cuts Gerber → “Define as cutting contour” (or set manually by right-clicking the board outline)
File → Open Excellon file → Import your drill file

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Layer alignment: After importing, check that your layers are correctly aligned. CopperCAM attempts automatic alignment based on fiducials and board coordinates. If layers appear misaligned, use the manual alignment tools. A common cause of misalignment: KiCad’s drill origin and Gerber origin are not set to the same point — always set both to “Drill/place file origin” during export.

Step 3 — Configure the Tool Library

Go to Parameters → Tool Library to define your physical cutting tools:

Engraving / isolation tool (V-bit):

Type: Conical
Tip diameter: 0.1mm to 0.3mm (manufacturer specification for your V-bit)
Angle: typically 10°, 15°, 30°, 45°, or 60° (check your bit specification)
CopperCAM calculates actual cut width automatically: (tan(angle) × 2) × depth + tip_diameter
Example: 30° V-bit, 0.1mm tip, 0.1mm depth → cut width ≈ 0.22mm

Why V-bits over straight end mills for isolation: V-bits provide very fine isolation lines (down to 0.15mm effective width with shallow cuts) that straight end mills cannot achieve at fine pitches. The tapered geometry also makes them more robust at small diameters. The trade-off: cut width varies with depth, so surface flatness of your PCB matters — consider surface height probing for better boards.

Drilling tools:

Add each drill bit size you have available (e.g., 0.8mm, 1.0mm, 1.2mm)
Specify diameter for each

Routing / cutout tool:

Typically a 1.0mm to 2.0mm straight end mill for board cutout
Specify diameter

Practical tool tip: Calibrate your V-bit by milling a test pattern and measuring actual cut widths under a magnifying glass or microscope. Adjust the effective diameter in CopperCAM to match measured reality. This is especially important for 30°+ angle bits where tip manufacturing tolerances have a larger effect on effective width.

Step 4 — Select Active Tools

Go to Parameters → Active tools (Selected tools):

Engraving tool settings:

Select your V-bit from the library
Depth: 0.05mm to 0.2mm (start shallow, test, increase if needed)
Margin: 0 for simple isolation; increase for wider clearance around pads
Speed: start conservative (5-10 mm/s), adjust based on results

Drilling strategy:

“Use for each drill the closest greater tool” — uses the nearest larger bit size with circular boring for oversized holes. Good when you have several drill sizes.
“Use a single tool for all drills” — simplest option when you only have one drill bit; bores all holes to that size

Cutting (routing) tool:

Select your board outline end mill
Set depth to slightly more than board thickness (e.g., 1.65mm for 1.6mm board)
Step down if your machine needs multiple passes for the board thickness

Step 5 — Calculate Isolation Contours

Click Calculate Contours (or the dedicated icon):

Number of successive contours: Typically 1-3. More contours = more copper removed around each trace = safer isolation but longer milling time. For boards with tight trace/space, 2-3 contours helps ensure reliable isolation.
Extra contours around pads: Add 1-2 extra passes specifically around component pads — pads are the highest-risk areas for solder bridges, and extra clearance here is almost always worth the extra machining time.
Force isolation between close pads: Enable this if your board has fine-pitch ICs (0.5mm to 0.8mm pitch). This ensures CopperCAM adds an isolation pass even between pads that are very close together.

After calculation, CopperCAM displays isolation paths in the view. Inspect them carefully — look for:

Any trace that doesn’t have isolation paths around it (a Gerber import issue)
Paths that cross into traces (tool diameter may be too large for trace spacing)
Red highlighted traces (CopperCAM flags these when isolation cannot be guaranteed — usually means traces are too close for your tool diameter)

Step 6 — Configure Hatching (Optional, for Ground Planes)

If your board has large copper pour areas (ground planes), CopperCAM can remove excess copper with hatching:

Roughing hatch: Uses a larger diameter tool (e.g., 1.0mm flat end mill) to quickly remove bulk copper
Finishing with engraving tool: Cleans up corners and edges the roughing tool couldn’t reach

For simple prototype boards without ground planes, skip hatching — it significantly increases machining time.

Step 7 — Define Board Contour and Support Bridges

Right-click the board edge trace → “Define as cutting contour.” The routing path is calculated to cut outside this line.

Support bridges: Before CopperCAM cuts the board completely free from the stock material, add support tabs (bridges) to prevent the board from moving or being grabbed by the cutter at the end of the cut. Go to Modify → Add bridge and click where you want bridges on the contour. Typically 2-4 bridges per board, 2-3mm wide. Cut them with a sharp knife after machining.

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Step 8 — Export G-Code

Go to Parameters → Output data format to configure output:

G-Code (most common):

Standard output compatible with GRBL, LinuxCNC, Mach3, bCNC, Candle
For GRBL machines: you may need to add spindle speed commands (e.g., S12000) and coordinate system selection (G54) to the output header — use the post-processor configuration to add these

Other supported formats:

HPGL — for HP plotters and some older machines
Roland RDGL — for Roland desktop mills (MDX-20, SRM-20 etc.) which use a proprietary format
Isel-NCP — for Isel CNC machines
DXF — geometric export for import into other CAM tools

Post-processor customization: CopperCAM’s output is fully customizable through its post-processor settings — add custom header/footer lines, change coordinate formats, add tool change commands, adjust feed rate formatting. This is how you adapt the output to machines that need non-standard initialization.

Automatic chaining: CopperCAM can automatically launch your CNC controller software after generating output, passing the file directly to it — useful for streamlining the workflow on a dedicated prototyping PC.

Double-Sided PCB Workflow

Double-sided PCBs require milling both sides and aligning them precisely. This is the most challenging aspect of CNC PCB fabrication:

Alignment Strategy: Centering Holes

CopperCAM supports a centering hole approach — the most reliable method for double-sided alignment:

Add two alignment holes to your PCB design (not connected to any net, just mechanical holes)
In CopperCAM: mill top side, then drill the alignment holes all the way through the board AND into the spoilboard
Insert alignment pins into the spoilboard holes
Flip the board — the pins go through the alignment holes, holding the board in exact position
Mill the bottom side

Important: When exporting the bottom layer, enable the Flip X option in CopperCAM — this mirrors the bottom layer correctly relative to the alignment reference.

Alignment hole placement: Use exactly two holes — at opposite corners of a horizontal or vertical line. Four holes overdetermine the constraint and can cause problems if hole positions aren’t perfectly matched on both sides. Two holes define a unique position.

Layer Mirroring

The bottom copper layer must be mirrored before milling. In CopperCAM, when importing the bottom Gerber:

The software automatically handles the mirroring when “Solder side” layer assignment is selected
The origin (0,0) must be in the same position for both sides — this is why consistent drill/place file origin in KiCad is critical

Zero Point Management

Mill the front side with (0,0) at the front-side zero point (typically bottom-left corner)
After flipping: the new zero point for the back side depends on your alignment method
With centering pins in spoilboard: (0,0) stays at the same physical location — the board flip + mirror handles the coordinate transform automatically

CopperCAM vs. Alternatives

Feature	CopperCAM	FlatCAM	pcb-gcode (Eagle plugin)	Carbide Copper
Price	Paid (affordable)	Free (open source)	Free (Eagle plugin)	Free (Carbide machines)
Gerber compatibility	Excellent (RS274-X + macros)	Good	Eagle-specific	Limited
KiCad rounded rect pads	✅ (Sep 2025+)	Varies	N/A	Unknown
Double-sided workflow	✅ Built-in	✅ Manual	Limited	Limited
Tool library management	✅ Full	✅ Full	Basic	Basic
Post-processor customization	✅ Full	✅ Full	Limited	Fixed
Roland direct output	✅ RDGL	No	No	No
Active maintenance	✅ Ongoing	Intermittent	Inactive	Carbide3D
Support bridges	✅ Manual	No	No	No
Ground plane hatching	✅	✅	No	No
Learning curve	Medium	Medium-High	Low (Eagle users)	Low

Choose CopperCAM if: You want reliable Gerber import across multiple PCB software tools, need Roland direct output, want ongoing software support, are making double-sided boards regularly, or have had frustrating import/alignment issues with free alternatives.

FlatCAM is sufficient if: Your CAD software produces clean RS274-X Gerber files and you’re making simple single-sided boards.

Common Issues and Solutions

Isolation Paths Not Generated for Some Traces

Cause: Trace spacing is smaller than your V-bit effective diameter at the configured depth. CopperCAM cannot fit an isolation pass between traces this close. Solution: Reduce milling depth (narrower effective cut width), use a finer tip V-bit, or redesign the board with slightly wider trace/space clearances.

Layers Not Aligning (Double-Sided Boards)

Cause: Gerber and drill file origins were set differently during export from KiCad/Eagle. Solution: In KiCad, ensure both Gerber plots and drill file generation use the same origin — “Drill/place file origin” for both. Verify by checking that the coordinate (0,0) appears at the same physical point in all exported files.

Wrong Pad Shapes After Import (KiCad)

Cause: KiCad uses parametric macros for rounded rectangle pads — older CopperCAM versions couldn’t read these. Solution: Update CopperCAM to version September 2025 or later. Alternatively, export pads as regular rectangles or ovals from KiCad as a workaround.

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G-Code Works in Simulation but Machine Doesn’t Execute Correctly

Cause: Machine-specific initialization requirements — spindle enable command, coordinate system, feedrate format. Solution: Use CopperCAM’s post-processor configuration to add machine-specific initialization. For GRBL: ensure G21 (mm mode), G90 (absolute), and spindle speed SXXX M3 are in the header. Some users add these via a small script that prepends/appends lines to the output G-code file.

Rough Isolation Edges / Poor Trace Definition

Cause: Feed rate too high, depth too deep, or tool wear. Solution: Reduce feed rate (start at 5 mm/s, work up). Reduce depth (0.05-0.08mm is often better than 0.15-0.2mm). Replace the V-bit — fine tip engraving bits wear quickly and produce wider, rougher cuts when worn.

Practical Tips from the PCB Milling Community

Surface probing: Copper-clad boards are rarely perfectly flat. Surface height probing (measuring the actual board height at multiple points and adjusting Z-height accordingly) dramatically improves isolation quality for fine-pitch work. Tools like bCNC, Candle (with AutoLeveler), and ChiliPeppr support this. Generate your G-code from CopperCAM normally, then run the probing + height compensation step in your controller software before executing.

V-bit selection: For fine-pitch work (0.5mm pitch ICs, 0.2mm trace/space), 10°-20° V-bits with 0.1mm tip give the best results — narrow effective cut width and good stiffness. 30°-60° bits are faster and more forgiving but can’t achieve as fine an isolation line.

Calibrate before committing: Mill CopperCAM’s test isolation pattern on scrap material to verify actual cut widths match expected values before milling your actual board.

Secure the board well: Any movement during milling ruins isolation quality and can break the tool. Double-sided tape on the spoilboard is common for smaller boards. Clamps work for larger boards but must not interfere with the tool path.

Manage chip evacuation: Milled copper and FR4 (fiberglass) produce fine dust and small chips. Gentle air blast or vacuum near the cut keeps chips from re-entering the isolation channel. Clean chips from channels before drilling — a brush works well.

Frequently Asked Questions

Does CopperCAM work with any CNC machine? Yes, as long as your machine accepts standard G-code (GRBL, Mach3, LinuxCNC, etc.), or HPGL (many Roland and HP machines). CopperCAM also has native Roland RDGL format output for Roland desktop mills. It does not directly connect to or drive any machine — it produces output files that you load into your controller software.

Can CopperCAM import files from Altium Designer or EasyEDA? Yes, as long as they export standard Gerber RS274-X format and Excellon drill files. Most professional PCB design tools do. The key is using RS274-X extended format, not the older RS274-D.

What is the minimum trace/space that CopperCAM can reliably isolate? This depends on your V-bit, not CopperCAM itself. CopperCAM accurately calculates isolation paths for whatever geometry you have. With a 10° V-bit at 0.05mm depth and 0.1mm tip, effective cut width is approximately 0.12mm — capable of isolating 0.15mm clearance designs. In practice, 0.2mm clearance is more forgiving and consistently reliable with consumer-grade desktop CNCs.

Is CopperCAM suitable for commercial/production PCB manufacturing? No — CopperCAM and isolation milling generally are for prototype and small-volume use. Commercial PCB fabrication houses provide better quality, tighter tolerances, solder mask, surface finish, and plated through-holes. CopperCAM fills the gap when you need a working prototype in hours rather than days.

How does the trial version limit affect testing? 25 isolation contours and 25 drill holes per export session. A simple board with 5-10 components and 20-30 drill holes will likely exceed the drill hole limit. You can export in multiple sessions (reopen CopperCAM, reload the file, export remaining data) to work around the trial limit for evaluation purposes.

Summary

CopperCAM fills a specific but important niche in the electronics maker workflow: the step between your PCB design software and your CNC machine. Its reliable Gerber import (including support for KiCad’s parametric macro pads as of September 2025), clean isolation contour calculation, double-sided PCB support with centering hole alignment, comprehensive tool library management, customizable post-processor output, and native support for Roland desktop mills make it the most capable dedicated PCB CAM tool available — and the first choice for makers who have outgrown the frustrations of free alternatives.

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