Hi,

I have an exp. of 3 years in PCB CAM dept. as a CAD/CAM engineer.
U have two problems..
1) What is the best way to merge two boards??
A) For two different design u have to manually do it ur self...OR
the pcb manufacturer will do it at their end..b'coz they have
facility to do it with the CAM software...u just give the detail
of panel u want as a read me doc.

2) How to create an array of the same design, say 3x3?
A) Its very simple... U have to use panel option in GERB TOOL..
TOOLS--->PANELIZE--->AUTO PANEL..
OR u can suggest ur panel to boardhouse...they can make it also.
minimum 2mm dist. must be calculated bet'n two pcb..routing dia..