Phase-1 left 75-358 unconnected_items per board (DRC), dominated by
GND/AGND/POWER nets that EPRO2 routes through copper pour, not discrete
traces. Phase-2 lands those:
- pcb_writer._decode_zone_path handles the three POUR.path encodings
seen in ESP-VoCat: rectangle (['R', x, y, w, h, ...]), circle
(['CIRCLE', cx, cy, r]) approximated as a 36-segment polygon, and
polyline (numeric pairs with 'L'/'ARC' verb tokens).
- Each POUR on a copper layer turns into a (zone (polygon ...) ...)
block plus a (filled_polygon ...) that mirrors the boundary.
Why mirror, not auto-fill: kicad-cli pcb drc does NOT run the zone
filler before checking — only the KiCad GUI does. Without a
pre-computed (filled_polygon ...), DRC sees zones as empty regions and
reports the entire net as unconnected. Mirroring the boundary as the
fill is "connectivity-correct, clearance-imprecise" — KiCad users can
still hit Edit > Fill Zones to refine thermals and pad clearances. We
chose this over reading EPRO2's POURED.pourFill (the editor's own
post-fill polygons) because POURED paths use ARC tokens we'd need to
fully decode, and the user-drawn POUR boundary is already the
authoritative "intended copper" region.
ESP-VoCat DRC totals: 883 → 730 unconnected_items (-17% project-wide).
CoreBoard, the 4-layer board with the most pour coverage, drops 358 →
205 (-43%). Other boards see no movement because their unconnected
items are non-pour issues — pads outside the user-drawn POUR
rectangle, or internal $1N nets via vias on the wrong net (separate
problem, separate fix).
65 → 68 unit tests pass.
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
Knowit
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