When converting my DXF file to Gerber, I keep getting a message "An exception occurred while creating Polygon". How do I fix this?

Gerber requires "clean & closed boundaries" with no overlapping or self intersections; in order to fill polygons.  ACE was unable to create filled polygons because there are multiple overlapping objects, and that's the reason for those error messages.  To correct the problem, simply delete the overlapping objects (using AutoCAD or any CAD program), and then perform the conversion.


Note:  For an example to locate the multiple overlapping objects, use AutoCAD (or any CAD program); then load your dxf and select the area around one of your boundaries and then press command "List".  In your example, there were three different objects to describe a single boundary: SOLID, LWPolyline, and Line  (see below for output).  This is very common problem when people create drawings and incorporate "SOLID Hatches" using AutoCAD.



LWPOLYLINE  Layer: "0"
                           Space: Model space
                  Handle = 315
             Open
   Constant width   0.00000
             area   2.91356
           length   30.57446

         at point  X=  2.63522  Y= 30.60821  Z=  0.00000
         at point  X=  2.70022  Y= 30.60821  Z=  0.00000
         at point  X=  2.76772  Y= 29.64571  Z=  0.00000
         at point  X=  2.76772  Y= 16.35321  Z=  0.00000
         at point  X=  2.70022  Y= 15.39071  Z=  0.00000
         at point  X=  2.63522  Y= 15.39071  Z=  0.00000
         at point  X=  2.56772  Y= 16.35321  Z=  0.00000
         at point  X=  2.56772  Y= 29.64571  Z=  0.00000
         at point  X=  2.63522  Y= 30.60821  Z=  0.00000

                 LINE      Layer: "0"
                           Space: Model space
                  Handle = 2ed
             from point, X=  2.70022  Y= 30.60821  Z=  0.00000
               to point, X=  2.76772  Y= 29.64571  Z=  0.00000
         Length =  0.96486,  Angle in XY Plane =    274
                 Delta X =  0.06750, Delta Y =  -0.96250, Delta Z =  0.00000

                 HATCH     Layer: "0"
                           Space: Model space
                  Handle = 316
Press ENTER to continue:
                Hatch pattern SOLID
                Associative
                Origin    X=  0.00000  Y=  0.00000  Z=  0.00000