Could it be a wize idea to convert every circle into 2 semi circles (or 4 quarter circles) while generating Gerbers if errors are so common?

Edit:

Did some homework, and the text below may be not worth reading.

In RS-274D “G-Code”, which is closely related to (at least the old) Gerber format, a well known limitation is that real circles do not exist, and arc’s are used instead.

G02 and G03, with either a “R” parameter for radius, or “I” and “J” coordinates which are relative positions of the arc center.

A further limitation is that arc’s with an included angle of close to 180degrees or 360 degrees, when specified with the “R”-adius parameter are very susceptible to rounding errors and are usually avoided.

At the moment I mostly assume that the person(s) who made the Gerber generators for KiCad know what they are doing, but I may be naive.

{ homework }

So I made a little test PCB, generated a gerber of Edge.Cuts and opened in a text editor.

I recognise the circle in the Gerber as:

G03X130000000Y-85000000I-5000000J0D01*

In G-code this would be:

- G03 - Counter Clockwise ARC.
- Full circle because X and Y are the same as (X, Y) before the ARC.
- Defined with I and J relative locations for the center.

( Only “R” has the rounding error sensitivity)

I do not recognize the “D01*”, but that is very likely because of differences between Gerber and “G-Code”.

{ /homework }