How can I output leading zeros in Ruby?

Use the % operator with a string:

irb(main):001:0> "%03d" % 5
=> "005"

The left-hand-side is a printf format string, and the right-hand side can be a list of values, so you could do something like:

irb(main):002:0> filename = "%s/%s.%04d.txt" % ["dirname", "filename", 23]
=> "dirname/filename.0023.txt"

Here's a printf format cheat sheet you might find useful in forming your format string. The printf format is originally from the C function printf, but similar formating functions are available in perl, ruby, python, java, php, etc.

Can't you just use string formatting of the value before you concat the filename?

"%03d" % number

If the maximum number of digits in the counter is known (e.g., n = 3 for counters 1..876), you can do

str = "file_" + i.to_s.rjust(n, "0")