Honour KiCad's keepouts: keyhole rings, wire_keepout, per-tile rasterizing
On the TerraHawk rc4 power stage every engine misread the board's rule areas: - A no-track ring along the board edge arrives as one keyhole polygon, and keepout polygons were wrapped in a single convex tile, so the ring became the whole board. Split keepout polygons into convex pieces instead. - The grid engine rasterized an area by its overall bounding box, which for that ring is again the whole board; it routed nothing. Rasterize per tile. - "Keep router off" rule areas arrive as wire_keepout, which the reader did not know, so tracks ran through them (172 DRC items_not_allowed). Read it at board and image level. For now it blocks vias too, which is stricter than KiCad and cannot create a violation. - place_keepout only restricts part placement; stop treating it as copper. The oracle now runs the JAR headless; it was opening FreeRouting's GUI on the desktop for every oracle test.
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@@ -27,6 +27,7 @@ import math
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from freeroute.dsn.model import DsnBoard
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from freeroute.dsn.shapes import Circle, Path, Polygon, Rectangle, Shape
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from freeroute.geometry import FloatPoint, IntBox, IntPoint, IntVector, Simplex
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from freeroute.geometry.polygon_shape import PolygonShape
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from .board import BasicBoard
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from .clearance import ClearanceMatrix
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@@ -219,11 +220,14 @@ def _insert_keepouts(dsn: DsnBoard, board: BasicBoard, transform: CoordinateTran
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signal_layers = [i for i, layer in enumerate(dsn.layers) if layer.is_signal]
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for keepout in dsn.keepouts:
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# A place_keepout only restricts where parts go, not copper.
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if keepout.kind == "place_keepout":
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continue
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area = keepout.area
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if area is None or area.border is None:
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continue
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tile = _area_border_tile(area.border, transform)
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if tile is None:
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tiles = _area_border_tiles(area.border, transform)
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if not tiles:
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continue
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border_layer = area.border.layer
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if border_layer in ("signal", "pcb"):
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@@ -237,11 +241,36 @@ def _insert_keepouts(dsn: DsnBoard, board: BasicBoard, transform: CoordinateTran
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ObstacleArea(
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name=keepout.area.name,
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layer=layer_index,
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tiles=[tile],
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tiles=tiles,
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)
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)
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def _area_border_tiles(shape: Shape, transform: CoordinateTransform) -> list:
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"""Convex board tiles covering a keepout border shape.
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Polygons are split into convex pieces rather than wrapped in one convex
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tile: KiCad exports a rule area with a hole (a no-track ring along the
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board edge, say) as a single keyhole polygon, and its convex hull is the
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whole board.
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"""
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if isinstance(shape, (Polygon, Path)):
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coords = shape.coords
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pts = [
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IntPoint(
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round(transform.dsn_to_board(coords[i])),
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round(transform.dsn_to_board(coords[i + 1])),
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)
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for i in range(0, len(coords) - 1, 2)
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]
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if len(pts) >= 3:
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pieces = [t for t in PolygonShape(pts).split_to_convex() if not t.is_empty()]
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if pieces:
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return pieces
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tile = _area_border_tile(shape, transform)
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return [tile] if tile is not None else []
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def _area_border_tile(shape: Shape, transform: CoordinateTransform):
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"""Convert an absolute-coordinate keepout border shape to one board tile."""
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if isinstance(shape, Rectangle):
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@@ -112,6 +112,7 @@ class Image:
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outlines: list[Shape] = field(default_factory=list)
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keepouts: list[Area] = field(default_factory=list)
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via_keepouts: list[Area] = field(default_factory=list)
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wire_keepouts: list[Area] = field(default_factory=list)
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place_keepouts: list[Area] = field(default_factory=list)
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@@ -174,7 +175,7 @@ class Keepout:
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"""A structure-level keepout area with its kind."""
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area: Area
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kind: str = "keepout" # keepout | via_keepout | place_keepout
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kind: str = "keepout" # keepout | via_keepout | wire_keepout | place_keepout
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@dataclass
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@@ -178,6 +178,11 @@ def _read_structure(node: SExp, board: DsnBoard) -> None:
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area = read_area(it)
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if area is not None:
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board.keepouts.append(Keepout(area=area, kind="via_keepout"))
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elif head == "wire_keepout":
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# KiCad writes a "no tracks" rule area this way (vias allowed).
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area = read_area(it)
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if area is not None:
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board.keepouts.append(Keepout(area=area, kind="wire_keepout"))
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elif head == "place_keepout":
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area = read_area(it)
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if area is not None:
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@@ -285,6 +290,10 @@ def _read_image(node: SExp) -> Image | None:
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area = read_area(it)
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if area is not None:
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image.via_keepouts.append(area)
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elif head == "wire_keepout":
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area = read_area(it)
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if area is not None:
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image.wire_keepouts.append(area)
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elif head == "place_keepout":
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area = read_area(it)
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if area is not None:
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@@ -199,11 +199,14 @@ class GridRouter:
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elif isinstance(item, ObstacleArea):
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if item.layer not in self.layers:
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continue
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box = item.bounding_box()
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if box.is_empty():
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continue
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for cell in self._cells_in_box(box, self.clearance):
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self._keepout.add((*cell, item.layer))
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# Tile by tile: the area's own bounding box of a ring (a
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# no-track border along the board edge) is the whole board.
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for tile in item.tiles:
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box = tile.bounding_box()
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if box.is_empty():
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continue
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for cell in self._cells_in_box(box, self.clearance):
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self._keepout.add((*cell, item.layer))
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# --- occupancy cost -----------------------------------------------------
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@@ -17,6 +17,7 @@ import pytest
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from freeroute.board import BasicBoard, ObstacleArea, Pin, build_board
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from freeroute.dsn import parse_dsn
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from freeroute.geometry import IntPoint
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sys.path.insert(0, str(Path(__file__).resolve().parent.parent))
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@@ -129,3 +130,60 @@ def test_board_net_set_covers_oracle_routed_nets(board):
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assert routed, "oracle produced no routed nets"
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# every net the reference router routed exists on our constructed board
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assert routed <= board.nets.names()
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# --- keepouts as KiCad exports them ------------------------------------------
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# Found on the TerraHawk charge-node boards (2026-09-27): a no-track ring along
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# the board edge arrives as one keyhole polygon, "keep router off" rule areas
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# arrive as wire_keepout, and neither may block the board's interior.
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_RING_DSN = """(pcb ring (parser) (resolution um 10) (unit um)
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(structure
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(layer F.Cu (type signal)) (layer B.Cu (type signal))
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(boundary (path pcb 0 0 0 40000 0 40000 -30000 0 -30000 0 0))
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(keepout "" (polygon F.Cu 0 0 0 40000 0 40000 -30000 0 -30000 0 0
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500 -500 500 -29500 39500 -29500 39500 -500 500 -500 0 0))
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(wire_keepout "pour" (polygon F.Cu 0 10000 -10000 20000 -10000 20000 -20000 10000 -20000))
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(place_keepout "courtyard" (polygon F.Cu 0 30000 -10000 35000 -10000 35000 -20000 30000 -20000))
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(rule (width 250) (clearance 150)))
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(placement) (library) (network))"""
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def _areas(dsn_text):
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return build_board(parse_dsn(dsn_text)).get_obstacle_areas()
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def _blocked(areas, x_um, y_um):
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p = IntPoint(x_um * 10, y_um * 10)
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return any(t.contains(p) for a in areas for t in a.tiles)
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def test_keyhole_ring_keepout_blocks_only_the_border():
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areas = _areas(_RING_DSN)
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assert _blocked(areas, 200, -15000) # inside the 0.5 mm edge strip
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assert not _blocked(areas, 5000, -5000) # open board interior
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def test_wire_keepout_is_read_and_blocks_its_area():
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dsn = parse_dsn(_RING_DSN)
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assert [k.kind for k in dsn.keepouts].count("wire_keepout") == 1
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assert _blocked(_areas(_RING_DSN), 15000, -15000)
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def test_place_keepout_does_not_block_routing():
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assert not _blocked(_areas(_RING_DSN), 32500, -15000)
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def test_grid_router_leaves_the_interior_of_a_ring_keepout_open():
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from freeroute.route.pipeline import route_dsn_board
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ring_only = "\n".join(
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line for line in _RING_DSN.splitlines() if "wire_keepout" not in line
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).replace(
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"(placement) (library) (network)",
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"(placement (component P (place P1 5000 -15000 front 0) (place P2 35000 -15000 front 0)))\n"
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" (library (image P (pin pad 1 0 0)) (padstack pad (shape (circle F.Cu 600)) (attach off)))\n"
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" (network (net N (pins P1-1 P2-1)))",
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)
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result, _, _ = route_dsn_board(parse_dsn(ring_only), max_passes=2)
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assert result.routed_net_numbers
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+6
-1
@@ -111,12 +111,17 @@ def route_dsn(dsn_path: str | Path, *, max_passes: int = 6, timeout: int = 180)
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with tempfile.NamedTemporaryFile(suffix=".ses", delete=False) as tmp:
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out_path = tmp.name
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try:
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# Headless: without these the JAR opens its GUI on the developer's
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# desktop for every oracle run.
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env = {k: v for k, v in os.environ.items() if k not in ("DISPLAY", "WAYLAND_DISPLAY")}
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subprocess.run(
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[JAVA, "-jar", JAR, "-de", str(dsn_path), "-do", out_path, "-mp", str(max_passes)],
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[JAVA, "-Djava.awt.headless=true", "-jar", JAR, "-de", str(dsn_path),
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"-do", out_path, "-mp", str(max_passes), "--gui.enabled=false"],
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capture_output=True,
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text=True,
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timeout=timeout,
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check=False,
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env=env,
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)
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text = Path(out_path).read_text()
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finally:
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