DKRed Upload Issue - "Missing Drill File" and "Empty Soldermask" Errors Despite Files Being Present

I’m encountering a persistent issue while trying to upload my PCB design files to DKRed and would appreciate any guidance.

After zipping my Gerber files (including a .drl drill file), I initially received an error stating that a drill file was missing. However, after uploading and using the PCB Builder Viewer, I was able to locate my 20D25L.drl file in the “Other” layers and successfully assign it as the “Drill File.” The viewer then seemed to recognize it.

Despite this, when I proceed, I now receive a new error stating:

Your file does not qualify for the DigiKey Red program.

To get an instant quote, the following requirements must be met: Must include Drill file The soldermask file is empty in the compressed file you submitted. Your PCB cannot be built without a soldermask file.

This is confusing because:

  1. The PCB Builder Viewer appears to have recognized and accepted my 20D25L.drl file after manual assignment.
  2. My zipped archive does contain both top (20D25L-F_Mask.gts) and bottom (20D25L-B_Mask.gbs) soldermask files. The initial zip process indicated they were not empty (they were “deflated”).

I have tried re-zipping the files with the .drl at the top level and have confirmed that the soldermask files exist in my local directory.

$ zip 20D25L.2.zip . -r
updating: 20D25L-Edge_Cuts.gm1 (deflated 64%)
updating: 20D25L-B_Silkscreen.gbo (deflated 67%)
updating: 20D25L-F_Mask.gts (deflated 77%)
updating: 20D25L-B_Mask.gbs (deflated 64%)
updating: 20D25L-F_Cu.gtl (deflated 77%)
updating: 20D25L-B_Cu.gbl (deflated 64%)
updating: 20D25L-F_Silkscreen.gto (deflated 77%)
updating: 20D25L-B_Paste.gbp (deflated 33%)
updating: 20D25L-F_Paste.gtp (deflated 33%)
updating: 20D25L.drl (deflated 22%)

Any suggestions on how to resolve this would be greatly appreciated. I’m not sure if there’s a specific naming convention or upload procedure I might be missing.

Welcome to the community.

If you would like you could direct message me your zip file, I can take a look at it.

If you click on my profile picture it allows you to message me.

Kindly see below instructions on fixing this if it’s the case you’re an Apple user:

Soldermask file is Empty in the Compressed File Error - Design Tools and Resources / DKRed and PCB Builder - DigiKey TechForum - An Electronic Component and Engineering Solution Forum