Route to the real board outline, per connection, and out of fine-pitch pins

- The exact engine verified copper per net and dropped a whole net on any
  conflict: a 25-pin +3V3 net lost every connection to one bad segment.
  Verify and accept per ratsnest connection instead.
- Pad and keepout cells were rounded outward, blocking cells up to half a
  step clear of the copper; 62 of the 64 pins of a 0.5 mm pitch LQFP could
  not start a route. Block only cells whose centre is inside the clearance
  zone, and let a net walk along inside its own pad, which adds no copper.
- Routing was bounded by the outline's bounding box, so tracks cut across
  rounded corners. Keep the DSN boundary as a polygon; the grid blocks cells
  too close to it (scanline plus per-edge, precomputed for vias) and the
  exact and room engines reject copper that is.
- --edge-clearance MM sets copper-to-edge clearance, e.g. KiCad's
  min_copper_edge_clearance, which the DSN does not carry. Default 0.

On the TerraHawk rc4 power stage the exact engine now matches the
FreeRouting JAR: same open count, no DRC errors, with a 0.5 mm edge rule.

src/freeroute/route/exact_router.py

@@ -91,6 +91,7 @@ def route_board_exact(
     max_shove_depth: int = 5,
     shove_cap: int = 3,
     via_half: int | None = None,
+    edge_clearance: int | None = None,
 ) -> ExactRouteResult:
     """Route ``board`` orthogonally and verify the result with exact geometry.
 
@@ -116,7 +117,10 @@ def route_board_exact(
         rip_up=rip_up,
         orthogonal=True,
         via_half=via_half,
+        edge_clearance=edge_clearance,
     )
+    edge = 0 if edge_clearance is None else edge_clearance
+    outline = board.outline
 
     tree = ShapeSearchTree()
     owner = _counter()
@@ -143,20 +147,25 @@ def route_board_exact(
     via_layers = frozenset(signal_layers)
     accepted: dict[int, _Accepted] = {}
 
-    for net_no in sorted(set(result.wires) | set(result.vias)):
-        boxes = _net_boxes(result, net_no, half_width, via_layers, via_half)
+    # Verify connection by connection, so one conflicting segment of a
+    # 25-pin supply net costs that one connection, not the whole net.
+    for net_no, wires, vias in sorted(result.connections, key=lambda c: c[0]):
+        boxes = _copper_boxes(wires, vias, half_width, via_layers, via_half)
         if any(
             tree.clearance_conflict(box, net_no, layer, clearance)
             for box, box_layers in boxes
             for layer in box_layers
-        ):
+        ) or (outline is not None and not all(outline.box_clear(b, edge) for b, _ in boxes)):
             continue  # exact-clearance conflict -> drop (may be recovered by shove)
-        acc = _Accepted(wires=result.wires.get(net_no, []), vias=result.vias.get(net_no, []))
+        acc = accepted.get(net_no)
+        if acc is None:
+            acc = accepted[net_no] = _Accepted(wires=[], vias=[])
+        acc.wires.extend(wires)
+        acc.vias.extend(vias)
         for box, box_layers in boxes:
             oid = next(owner)
             tree.insert(TreeShape(oid, net_no, box_layers, box, routed=True))
             acc.owners.append(oid)
-        accepted[net_no] = acc
 
     # a net is dropped if it has a real ratsnest (>= 2 pins on a signal layer)
     # but was not accepted — whether the grid failed to route it or its exact
@@ -547,12 +556,18 @@ def _rollback(shoved, accepted, tree, owner) -> int:  # noqa: ARG001
 
 
 def _net_boxes(result, net_no, half_width, via_layers, via_half=None):
+    return _copper_boxes(
+        result.wires.get(net_no, []), result.vias.get(net_no, []), half_width, via_layers, via_half
+    )
+
+
+def _copper_boxes(wires, vias, half_width, via_layers, via_half=None):
     via_half = via_half or half_width
     boxes: list[tuple[IntBox, frozenset[int]]] = []
-    for layer, points in result.wires.get(net_no, []):
+    for layer, points in wires:
         for box in PolylineShape(Polyline(points), half_width).tiles():
             boxes.append((box, frozenset({layer})))
-    for loc in result.vias.get(net_no, []):
+    for loc in vias:
         vbox = IntBox(loc.x - via_half, loc.y - via_half, loc.x + via_half, loc.y + via_half)
         boxes.append((vbox, via_layers))
     return boxes

src/freeroute/route/grid_router.py

@@ -31,7 +31,7 @@ import math
 
 from freeroute.board.board import BasicBoard
 from freeroute.board.items import ObstacleArea, Pin
-from freeroute.geometry import IntPoint
+from freeroute.geometry import IntBox, IntPoint
 
 __all__ = ["GridRouter", "RouteResult", "route_board"]
 
@@ -59,7 +59,7 @@ class RouteResult:
     ``routed_net_numbers`` are the nets that got any wire or via.
     """
 
-    __slots__ = ("wires", "vias", "half_width", "unrouted")
+    __slots__ = ("wires", "vias", "half_width", "unrouted", "connections")
 
     def __init__(self, half_width: int) -> None:
         self.wires: dict[int, list[tuple[int, list[IntPoint]]]] = {}
@@ -67,6 +67,8 @@ class RouteResult:
         self.half_width = half_width
         #: number of ratsnest connections left unrouted
         self.unrouted = 0
+        #: the same copper per routed connection: (net_no, wires, vias)
+        self.connections: list[tuple[int, list[tuple[int, list[IntPoint]]], list[IntPoint]]] = []
 
     def add_wire(self, net_no: int, layer: int, path: list[IntPoint]) -> None:
         self.wires.setdefault(net_no, []).append((layer, path))
@@ -132,6 +134,7 @@ class GridRouter:
         rip_penalty: float = 30.0,
         orthogonal: bool = False,
         via_half: int | None = None,
+        edge_clearance: int | None = None,
     ) -> None:
         self.board = board
         self.trace_width = max(trace_width, 1)
@@ -151,6 +154,8 @@ class GridRouter:
         # centre via_half + clearance + half_width from the via's centre, so a
         # via also claims every cell within via_reach of its own.
         self.via_half = via_half or self.half_width
+        # copper to board edge; KiCad's rule is usually wider than clearance
+        self.edge_clearance = 0 if edge_clearance is None else edge_clearance
         need = self.via_half + self.clearance + self.half_width
         self.via_reach = max(0, math.ceil(need / self.step) - 1)
 
@@ -166,6 +171,7 @@ class GridRouter:
 
         # static obstacles
         self._pad_block: dict[Node, set[int]] = {}
+        self._pad_own: dict[Node, set[int]] = {}
         self._keepout: set[Node] = set()
         # per-connection occupancy (owner = connection index)
         self._cell_owner: dict[Node, int] = {}
@@ -185,16 +191,57 @@ class GridRouter:
         return IntPoint(self.origin_x + cell[0] * self.step, self.origin_y + cell[1] * self.step)
 
     def _cells_in_box(self, box, margin: int):
-        lo_x = round((box.ll.x - margin - self.origin_x) / self.step)
-        hi_x = round((box.ur.x + margin - self.origin_x) / self.step)
-        lo_y = round((box.ll.y - margin - self.origin_y) / self.step)
-        hi_y = round((box.ur.y + margin - self.origin_y) / self.step)
+        """Cells whose centre lies strictly inside ``box`` grown by ``margin``.
+
+        A trace centred there would come closer than ``margin`` to the box.
+        Rounding the bounds outward instead blocked cells up to half a step
+        clear of it, which walled in every pin of a 0.5 mm pitch package.
+        """
+        lo_x = math.floor((box.ll.x - margin - self.origin_x) / self.step) + 1
+        hi_x = math.ceil((box.ur.x + margin - self.origin_x) / self.step) - 1
+        lo_y = math.floor((box.ll.y - margin - self.origin_y) / self.step) + 1
+        hi_y = math.ceil((box.ur.y + margin - self.origin_y) / self.step) - 1
         for gx in range(max(lo_x, 0), min(hi_x, self.cols - 1) + 1):
             for gy in range(max(lo_y, 0), min(hi_y, self.rows - 1) + 1):
                 yield gx, gy
 
+    def _outline_blocked(self, reach: int) -> set[Cell]:
+        """Cells whose centre is outside the outline or within ``reach`` of its edge."""
+        outline = self.board.outline
+        blocked: set[Cell] = set()
+        for gy in range(self.rows):  # outside: one scanline per row
+            y = self.origin_y + gy * self.step
+            spans = outline.row_inside_spans(y)
+            for gx in range(self.cols):
+                x = self.origin_x + gx * self.step
+                if not any(lo < x < hi for lo, hi in spans):
+                    blocked.add((gx, gy))
+        for a, b in outline.edges():  # too close: only cells near each edge
+            edge_box = IntBox(min(a.x, b.x), min(a.y, b.y), max(a.x, b.x), max(a.y, b.y))
+            for cell in self._cells_in_box(edge_box, reach):
+                if cell not in blocked and outline.edge_distance(self._cell_center(cell)) < reach:
+                    blocked.add(cell)
+        return blocked
+
+    def _inside_own_pad(self, cell: Cell, shape) -> bool:
+        """A trace centred on ``cell`` lies entirely on the pad's own copper."""
+        c = self._cell_center(cell)
+        h = self.half_width
+        return all(
+            shape.contains(IntPoint(c.x + dx, c.y + dy)) for dx in (-h, h) for dy in (-h, h)
+        )
+
     def _rasterize_obstacles(self) -> None:
         margin = self.clearance + self.half_width
+        outline = self.board.outline
+        self._via_edge_block: set[Cell] = set()
+        if outline is not None:
+            # cells too close to the real outline (rounded corners included):
+            # for a trace on every layer, and separately for a via's wider copper
+            for cell in self._outline_blocked(self.half_width + self.edge_clearance):
+                for layer in self.layers:
+                    self._keepout.add((*cell, layer))
+            self._via_edge_block = self._outline_blocked(self.via_half + self.edge_clearance)
         for item in self.board.get_items():
             if isinstance(item, Pin):
                 box = item.shape.bounding_box() if item.shape is not None else None
@@ -205,6 +252,13 @@ class GridRouter:
                 for cell in self._cells_in_box(box, margin):
                     for layer in pin_layers:
                         self._pad_block.setdefault((*cell, layer), set()).add(net)
+                # Copper of the pin's own net: a trace inside it adds nothing,
+                # so it is open to that net however close the neighbours are.
+                # That is how a route leaves a fine-pitch pin.
+                for cell in self._cells_in_box(box, 0):
+                    if self._inside_own_pad(cell, item.shape):
+                        for layer in pin_layers:
+                            self._pad_own.setdefault((*cell, layer), set()).add(net)
             elif isinstance(item, ObstacleArea):
                 if item.layer not in self.layers:
                     continue
@@ -214,7 +268,8 @@ class GridRouter:
                     box = tile.bounding_box()
                     if box.is_empty():
                         continue
-                    for cell in self._cells_in_box(box, self.clearance):
+                    # the same distance the exact engine verifies against
+                    for cell in self._cells_in_box(box, margin):
                         self._keepout.add((*cell, item.layer))
 
     # --- occupancy cost -----------------------------------------------------
@@ -233,7 +288,7 @@ class GridRouter:
         if node in self._keepout:
             return None
         pads = self._pad_block.get(node)
-        if pads and any(n != net_no for n in pads):
+        if pads and any(n != net_no for n in pads) and net_no not in self._pad_own.get(node, ()):
             return None
         blocking = None
         owner = self._cell_owner.get(node)
@@ -264,6 +319,8 @@ class GridRouter:
 
     def _via_placeable(self, cell: Cell, net_no: int, conns: list[_Connection]) -> bool:
         """A through via needs its whole footprint free of other nets on every layer."""
+        if cell in self._via_edge_block:
+            return False
         return all(
             self._enter_cost(c, layer, net_no, False, conns) == 0.0
             for c in self._via_cells(cell)
@@ -464,6 +521,7 @@ class GridRouter:
                 result.add_wire(net_no, layer, points)
             for location in vias:
                 result.add_via(net_no, location)
+            result.connections.append((net_no, wires, vias))
         return result
 
 
@@ -520,6 +578,7 @@ def route_board(
     max_passes: int = 10,
     orthogonal: bool = False,
     via_half: int | None = None,
+    edge_clearance: int | None = None,
 ) -> RouteResult:
     """Convenience wrapper: build a :class:`GridRouter` and route the board."""
     router = GridRouter(
@@ -532,5 +591,6 @@ def route_board(
         max_passes=max_passes,
         orthogonal=orthogonal,
         via_half=via_half,
+        edge_clearance=edge_clearance,
     )
     return router.route()

src/freeroute/route/pipeline.py

@@ -45,6 +45,14 @@ def _via_padstack(dsn: DsnBoard) -> str:
     return dsn.via_padstack_names[0] if dsn.via_padstack_names else _DEFAULT_VIA
 
 
+def _mm_to_board(dsn: DsnBoard, scale: int, value_mm: float | None) -> int | None:
+    """A length in millimetres as board units, or None."""
+    if value_mm is None:
+        return None
+    unit_mm = {"inch": 25.4, "mil": 0.0254, "mm": 1.0, "cm": 10.0, "um": 0.001}[dsn.unit]
+    return round(value_mm / unit_mm * scale)
+
+
 def _via_half_board(dsn: DsnBoard, scale: int) -> int | None:
     """Half the via pad's size in board units, from the DSN's via padstack.
 
@@ -67,6 +75,7 @@ def _via_half_board(dsn: DsnBoard, scale: int) -> int | None:
 def route_dsn_board(
     dsn: DsnBoard,
     *,
+    edge_clearance_mm: float | None = None,
     layers: list[int] | None = None,
     rip_up: bool = True,
     max_passes: int = 10,
@@ -77,11 +86,13 @@ def route_dsn_board(
     toggles rip-up-and-retry (``False`` = greedy single pass)."""
     board = build_board(dsn)
     scale = max(dsn.resolution.value, 1)
+    edge_clearance_board = _mm_to_board(dsn, scale, edge_clearance_mm)
     width_board = round(_rule_width_dsn(dsn) * scale)
     clearance_board = round(_rule_clearance_dsn(dsn) * scale)
     result = route_board(
         board,
         via_half=_via_half_board(dsn, scale),
+        edge_clearance=edge_clearance_board,
         trace_width=width_board,
         clearance=clearance_board,
         layers=layers,
@@ -122,10 +133,12 @@ def build_routing_result(
     layers: list[int] | None = None,
     rip_up: bool = True,
     max_passes: int = 10,
+    edge_clearance_mm: float | None = None,
 ) -> RoutingResult:
     """Route ``dsn`` (grid track) and convert to a DSN-unit RoutingResult."""
     route, scale, layer_names = route_dsn_board(
-        dsn, layers=layers, rip_up=rip_up, max_passes=max_passes
+        dsn, layers=layers, rip_up=rip_up, max_passes=max_passes,
+        edge_clearance_mm=edge_clearance_mm,
     )
     return _to_routing_result(route, dsn, scale, layer_names)
 
@@ -133,6 +146,7 @@ def build_routing_result(
 def route_dsn_board_exact(
     dsn: DsnBoard,
     *,
+    edge_clearance_mm: float | None = None,
     layers: list[int] | None = None,
     max_passes: int = 10,
     rip_up: bool = True,
@@ -146,11 +160,13 @@ def route_dsn_board_exact(
     the 45-degree recovery pass for still-dropped 2-pin nets."""
     board = build_board(dsn)
     scale = max(dsn.resolution.value, 1)
+    edge_clearance_board = _mm_to_board(dsn, scale, edge_clearance_mm)
     width_board = round(_rule_width_dsn(dsn) * scale)
     clearance_board = round(_rule_clearance_dsn(dsn) * scale)
     exact = route_board_exact(
         board,
         via_half=_via_half_board(dsn, scale),
+        edge_clearance=edge_clearance_board,
         trace_width=width_board,
         clearance=clearance_board,
         layers=layers,
@@ -170,6 +186,7 @@ def build_exact_routing_result(
     diagonal: bool = False,
     rip_up: bool = True,
     max_passes: int = 10,
+    edge_clearance_mm: float | None = None,
 ) -> RoutingResult:
     """Route ``dsn`` (exact track) and convert to a DSN-unit RoutingResult."""
     exact, scale, layer_names = route_dsn_board_exact(
@@ -179,12 +196,18 @@ def build_exact_routing_result(
         diagonal=diagonal,
         rip_up=rip_up,
         max_passes=max_passes,
+        edge_clearance_mm=edge_clearance_mm,
     )
     return _to_routing_result(exact.result, dsn, scale, layer_names)
 
 
 def route_dsn_board_rooms(
-    dsn: DsnBoard, *, layers: list[int] | None = None, shove: bool = False, pack: bool = False
+    dsn: DsnBoard,
+    *,
+    layers: list[int] | None = None,
+    shove: bool = False,
+    pack: bool = False,
+    edge_clearance_mm: float | None = None,
 ) -> tuple[ExactRouteResult, int, list[str]]:
     """Route a parsed :class:`DsnBoard` with the continuous expansion-room track;
     return the result, the scale, and layer names. ``shove`` enables occupancy-
@@ -192,11 +215,13 @@ def route_dsn_board_rooms(
     ``pack`` enables the coordinated multi-trace channel packer."""
     board = build_board(dsn)
     scale = max(dsn.resolution.value, 1)
+    edge_clearance_board = _mm_to_board(dsn, scale, edge_clearance_mm)
     width_board = round(_rule_width_dsn(dsn) * scale)
     clearance_board = round(_rule_clearance_dsn(dsn) * scale)
     rooms = route_board_rooms(
         board,
         via_half=_via_half_board(dsn, scale),
+        edge_clearance=edge_clearance_board,
         trace_width=width_board,
         clearance=clearance_board,
         layers=layers,
@@ -207,10 +232,17 @@ def route_dsn_board_rooms(
 
 
 def build_rooms_routing_result(
-    dsn: DsnBoard, *, layers: list[int] | None = None, shove: bool = False, pack: bool = False
+    dsn: DsnBoard,
+    *,
+    layers: list[int] | None = None,
+    shove: bool = False,
+    pack: bool = False,
+    edge_clearance_mm: float | None = None,
 ) -> RoutingResult:
     """Route ``dsn`` (room track) and convert to a DSN-unit RoutingResult."""
-    rooms, scale, layer_names = route_dsn_board_rooms(dsn, layers=layers, shove=shove, pack=pack)
+    rooms, scale, layer_names = route_dsn_board_rooms(
+        dsn, layers=layers, shove=shove, pack=pack, edge_clearance_mm=edge_clearance_mm
+    )
     return _to_routing_result(rooms.result, dsn, scale, layer_names)
 
 
@@ -222,6 +254,7 @@ def route(
     shove: bool = False,
     pack: bool = False,
     diagonal: bool = False,
+    edge_clearance_mm: float | None = None,
 ) -> str:
     """Route a Specctra DSN string and return the routed SES string.
 
@@ -235,9 +268,13 @@ def route(
     """
     dsn = parse_dsn(dsn_text)
     if engine == "exact":
-        result = build_exact_routing_result(dsn, layers=layers, shove=shove, diagonal=diagonal)
+        result = build_exact_routing_result(
+            dsn, layers=layers, shove=shove, diagonal=diagonal, edge_clearance_mm=edge_clearance_mm
+        )
     elif engine == "room":
-        result = build_rooms_routing_result(dsn, layers=layers, shove=shove, pack=pack)
+        result = build_rooms_routing_result(
+            dsn, layers=layers, shove=shove, pack=pack, edge_clearance_mm=edge_clearance_mm
+        )
     else:
-        result = build_routing_result(dsn, layers=layers)
+        result = build_routing_result(dsn, layers=layers, edge_clearance_mm=edge_clearance_mm)
     return write_ses(dsn, result)

src/freeroute/route/room_router.py

@@ -472,6 +472,7 @@ def route_board_rooms(
     max_shove_depth: int = 5,
     shove_cap: int = 3,
     via_half: int | None = None,
+    edge_clearance: int | None = None,
 ) -> ExactRouteResult:
     """Route ``board`` with the continuous expansion-room track.
 
@@ -498,6 +499,7 @@ def route_board_rooms(
     # half the via pad's size: a via is not a trace, and sizing it like one
     # let routes pass within a via's real copper
     via_half = via_half or half_width
+    edge = (board.outline, 0 if edge_clearance is None else edge_clearance)
     margin = clearance + half_width
     outline = board.bounding_box
 
@@ -541,7 +543,7 @@ def route_board_rooms(
             via_layers,
             accepted,
             shove,
-        via_half=via_half)
+        via_half=via_half, edge=edge)
     for net_no in sorted(_routable_nets(board, signal_layers)):
         if net_no in packed:
             continue
@@ -566,7 +568,7 @@ def route_board_rooms(
                 accepted,
                 max_shove_depth,
                 shove_cap,
-            via_half=via_half)
+            via_half=via_half, edge=edge)
 
     drc_clean = tree.has_violation(clearance) is None
     return ExactRouteResult(result=result, tree=tree, drc_clean=drc_clean, shoves=shoves)
@@ -592,6 +594,7 @@ def _route_connection(
     max_shove_depth=5,
     shove_cap=3,
     via_half=None,
+    edge=None,
 ):
     rooms_by_layer = {
         layer: _free_rooms(tree, outline, layer, net_no, margin, half_width)
@@ -612,7 +615,7 @@ def _route_connection(
 
     if realized is not None:
         wires, vias = realized
-        boxes = _collect_boxes(wires, vias, half_width, via_layers, outline, via_half=via_half)
+        boxes = _collect_boxes(wires, vias, half_width, via_layers, outline, via_half=via_half, edge=edge)
         if boxes is not None and not any(
             tree.clearance_conflict(box, net_no, layer, clearance)
             for box, box_layers in boxes
@@ -639,11 +642,11 @@ def _route_connection(
             clearance,
             max_shove_depth,
             shove_cap,
-        via_half=via_half)
+        via_half=via_half, edge=edge)
     return 0
 
 
-def _collect_boxes(wires, vias, half_width, via_layers, outline, via_half=None):
+def _collect_boxes(wires, vias, half_width, via_layers, outline, via_half=None, edge=None):
     via_half = via_half or half_width
     """The ``(box, layers)`` copper tiles of a realized route, or ``None`` if any
     tile leaves the board outline (the same early-out as the old inline check)."""
@@ -652,6 +655,8 @@ def _collect_boxes(wires, vias, half_width, via_layers, outline, via_half=None):
         for box in PolylineShape(Polyline(corners), half_width).tiles():
             if not outline.contains_box(box):
                 return None
+            if edge is not None and edge[0] is not None and not edge[0].box_clear(box, edge[1]):
+                return None
             boxes.append((box, frozenset({layer})))
     for loc in vias:
         vbox = IntBox(
@@ -864,6 +869,7 @@ def _pack_channels(
     accepted,
     shove,
     via_half=None,
+    edge=None,
 ) -> set[int]:
     """Coordinated multi-trace channel packing (opt-in pre-pass).
 
@@ -932,7 +938,7 @@ def _pack_channels(
                     spacing_min,
                     via_layers,
                     outline,
-                via_half=via_half)
+                via_half=via_half, edge=edge)
                 if placed is None:
                     continue  # could not pack every member cleanly -> leave to greedy
                 for net_no, wires in placed:
@@ -969,6 +975,7 @@ def _pack_group(
     via_layers,
     outline,
     via_half=None,
+    edge=None,
 ):
     """Assign parallel lanes + staggered fan-in trunks to every net crossing one
     gap, and return ``[(net_no, wires), ...]`` if ALL of them realize exactly
@@ -1025,7 +1032,7 @@ def _pack_group(
         if len(corners) < 2:
             return None
         wires = [(layer, corners)]
-        boxes = _collect_boxes(wires, [], half_width, via_layers, outline, via_half=via_half)
+        boxes = _collect_boxes(wires, [], half_width, via_layers, outline, via_half=via_half, edge=edge)
         if boxes is None:
             return None
         if any(
@@ -1061,6 +1068,7 @@ def _shove_recover_room(
     max_shove_depth,
     shove_cap,
     via_half=None,
+    edge=None,
 ) -> int:
     """Recover a dropped net by nudging the committed trace(s) that block it.