Pin access: --access-cost, vias in pads inside wire keepouts, exact stub checks

--access-cost C makes a route pay C to pass where it would close another
pin's way out (its end cells, the via it may need there, and the
clearance around both) while that pin still has connections to route.

A pin inside a wire keepout can only leave by a via; its stub to the
cell centre was track inside the keepout, which the exact check refused.
The via now goes on the pin itself. Pin stubs are also checked exactly
against wire keepouts, as the exact engine will check them.

bench/diagnose.py reports what each refused connection collided with.

bench/bench.py

@@ -24,9 +24,11 @@ off. Exits non-zero if any run crashed or timed out.
 from __future__ import annotations
 
 import argparse
+from concurrent.futures import ThreadPoolExecutor, as_completed
 import json
 import math
 import os
+from pathlib import Path
 import re
 import shlex
 import subprocess
@@ -34,8 +36,6 @@ import sys
 import tempfile
 import threading
 import time
-from concurrent.futures import ThreadPoolExecutor, as_completed
-from pathlib import Path
 
 NOT_ROUTED = re.compile(r"freeroute: (\d+) connection\(s\) not routed")
 TO_ZONE = re.compile(r"freeroute: (\d+) more connection\(s\) left to a zone fill")

bench/diagnose.py

@@ -0,0 +1,253 @@
+"""Why did each connection fail? Sort the failures of one exact-engine run.
+
+    uv run python bench/diagnose.py board.dsn --edge-clearance 0.5 [--json out.json]
+
+Every connection the exact engine leaves unrouted lands in one bucket:
+
+rejected    the grid routed it, the exact geometry check refused its copper
+alone       it cannot be routed even on a board with no other routes: the
+            pads, keepouts or the grid itself are the limit, not congestion
+walled-in   in the routed board one of its pins has no way out: a flood from
+            the pin's end cells through free cells stops short (pin access)
+congestion  both pins can get out, but no free path joins them
+
+The board state is the one the result came from (the best pass), rebuilt by
+replaying that pass's paths. Diagnostic only: it reaches into the router.
+"""
+
+from __future__ import annotations
+
+import argparse
+from collections import Counter
+import json
+from pathlib import Path
+import sys
+
+from freeroute.board import build_board
+from freeroute.board.search_tree import ShapeSearchTree
+from freeroute.dsn import parse_dsn
+from freeroute.route import grid_router
+from freeroute.route.exact_router import route_board_exact
+from freeroute.route.grid_router import GridRouter, _ends_of
+from freeroute.route.pipeline import (
+    _mm_to_board,
+    _rule_clearance_dsn,
+    _rule_width_dsn,
+    _via_half_board,
+)
+
+# a pin whose free neighbourhood holds fewer nodes than this is walled in
+FLOOD_LIMIT = 200
+
+
+def _capture_router():
+    """Patch GridRouter so the instance route_board_exact builds, and the paths
+    of its best pass, can be read back afterwards."""
+    seen: dict = {}
+    original_commit = GridRouter._commit
+    original_snapshot = GridRouter._snapshot
+
+    def commit(self, conn, path):
+        original_commit(self, conn, path)
+        self._diag_paths[conn.index] = (list(path), conn.a_end, conn.b_end)
+
+    def snapshot(self, conns):
+        self._diag_best = {c.index: self._diag_paths[c.index] for c in conns if c.routed}
+        seen["router"] = self
+        return original_snapshot(self, conns)
+
+    def init(self, *args, **kwargs):
+        original_init(self, *args, **kwargs)
+        self._diag_paths = {}
+        self._diag_best = {}
+        seen["kwargs"] = kwargs
+        seen["args"] = args
+
+    original_init = GridRouter.__init__
+    GridRouter.__init__ = init
+    GridRouter._commit = commit
+    GridRouter._snapshot = snapshot
+    return seen
+
+
+def _capture_conflicts() -> list:
+    """Record each exact-check refusal: the copper box, its kind, and the
+    shape it came too close to. The check stops at a connection's first
+    conflict, so refusals and rejected connections line up in order."""
+    log: list = []
+    original = ShapeSearchTree.clearance_conflict
+
+    def conflict(self, box, net_no, layer, clearance, kind="wire"):
+        hit = original(self, box, net_no, layer, clearance, kind)
+        if hit:
+            expanded = box.offset(clearance)
+            other = next(
+                (s for s in self.overlapping(expanded)
+                 if s.net_no != net_no and s.on_layer(layer)
+                 and (s.blocks == "all" or s.blocks == kind + "s")),
+                None,
+            )
+            log.append((net_no, kind, layer, box, clearance, other))
+        return hit
+
+    ShapeSearchTree.clearance_conflict = conflict
+    return log
+
+
+def _gap(a, b) -> int:
+    dx = max(b.ll.x - a.ur.x, a.ll.x - b.ur.x, 0)
+    dy = max(b.ll.y - a.ur.y, a.ll.y - b.ur.y, 0)
+    return max(dx, dy)
+
+
+def _fresh(seen) -> GridRouter:
+    router = grid_router.GridRouter(*seen["args"], **seen["kwargs"])
+    router._conns = router._build_connections()
+    return router
+
+
+def _flood(router: GridRouter, pin, net_no: int, conns) -> tuple[int, Counter]:
+    """How many nodes a pin can reach through free cells (up to FLOOD_LIMIT),
+    and which other nets' copper bounds the region."""
+    walls: Counter = Counter()
+    # the search starts on every end node unconditionally (it may leave one
+    # inside a wire keepout by a via), so the flood does too
+    start = list(router._end_nodes(pin, net_no, conns))
+    seen = set(start)
+    frontier = list(start)
+    while frontier and len(seen) < FLOOD_LIMIT:
+        x, y, layer = frontier.pop()
+        steps = [(x + dx, y + dy, layer) for dx, dy in router._neighbours]
+        if router._via_placeable((x, y), net_no, conns):
+            steps += [(x, y, other) for other in router.layers if other != layer]
+        elif len(seen) == 1:
+            # the pin's own exit is a via that other copper leaves no room for
+            via_nodes = [(*c, lay) for c in router._via_cells((x, y)) for lay in router.layers]
+            for owner in router._crossed_owners(via_nodes, net_no, conns):
+                walls[conns[owner].net_no] += 1
+        for n in steps:
+            if n in seen or not (0 <= n[0] < router.cols and 0 <= n[1] < router.rows):
+                continue
+            if router._enter_cost(n[:2], n[2], net_no, False, conns) is None:
+                # trace, via footprint or clearance halo, as rip-up sees them
+                owners = router._crossed_owners([n], net_no, conns)
+                for owner in owners:
+                    walls[conns[owner].net_no] += 1
+                if not owners:
+                    walls[0] += 1  # a pad or keepout
+                continue
+            seen.add(n)
+            frontier.append(n)
+    return len(seen), walls
+
+
+def diagnose(
+    dsn_text: str, edge_clearance_mm: float | None, resolution: int = 2, shove: bool = False,
+    access_cost: float = 0.0,
+) -> dict:
+    dsn = parse_dsn(dsn_text)
+    names = {i + 1: n.name for i, n in enumerate(dsn.nets)}
+    scale = max(dsn.resolution.value, 1)
+    seen = _capture_router()
+    conflicts = _capture_conflicts()
+    exact = route_board_exact(
+        build_board(dsn),
+        trace_width=round(_rule_width_dsn(dsn) * scale),
+        clearance=round(_rule_clearance_dsn(dsn) * scale),
+        via_half=_via_half_board(dsn, scale),
+        edge_clearance=_mm_to_board(dsn, scale, edge_clearance_mm),
+        resolution=resolution,
+        shove=shove,
+        access_cost=access_cost,
+    )
+    routed = seen["router"]
+    best = routed._diag_best
+    grid_failed = {(c.net_no, *_ends_of(c)) for c in routed._conns if c.index not in best}
+
+    # the board as the best pass left it
+    state = _fresh(seen)
+    conns = state._conns
+    for idx, (path, a_end, b_end) in best.items():
+        conns[idx].a_end, conns[idx].b_end = a_end, b_end
+        state._commit(conns[idx], path)
+    empty = _fresh(seen)
+    # refusals in the order the check made them, one per rejected connection
+    per_net: dict[int, list] = {}
+    for net_no, kind, layer, box, clearance, other in conflicts:
+        if other is None:
+            what = "?"
+        elif other.net_no == -1:
+            what = "keepout"
+        else:
+            what = ("trace/via of " if other.routed else "pad of ") + names.get(other.net_no, "?")
+        short = (clearance - _gap(box, other.tile)) / scale / 1000 if other is not None else 0
+        per_net.setdefault(net_no, []).append(
+            {"copper": kind, "layer": layer, "against": what, "short_mm": round(short, 4)}
+        )
+    by_key = {(c.net_no, *_ends_of(c)): c for c in conns}
+
+    rows = []
+    for failure in exact.result.failed:
+        net_no, a, b = failure[0], failure[1], failure[2]
+        zone = failure[3] if len(failure) > 3 else ""
+        if zone:
+            continue  # left to a zone fill, not a failure
+        key = (net_no, a, b)
+        row = {"net": names.get(net_no, str(net_no)), "a": a, "b": b}
+        conn = by_key.get(key)
+        if key not in grid_failed:
+            row["kind"] = "rejected"
+            if per_net.get(net_no):
+                row["conflict"] = per_net[net_no].pop(0)
+        elif conn is None:
+            row["kind"] = "unknown"
+        elif empty._search(empty._conns[conn.index], allow_ripup=False, conns=empty._conns) is None:
+            row["kind"] = "alone"
+        else:
+            walled = []
+            for end, group in ((a, conn.a_group), (b, conn.b_group)):
+                for pin in group[0][:1]:  # a group's first pin is its route end
+                    reach, walls = _flood(state, pin, net_no, conns)
+                    if reach < FLOOD_LIMIT:
+                        walled.append({
+                            "pin": end, "reach": reach,
+                            "walls": [names.get(n, "pads/keepouts") for n, _ in walls.most_common(4)],
+                        })
+            row["kind"] = "walled-in" if walled else "congestion"
+            if walled:
+                row["walled"] = walled
+        rows.append(row)
+    return {"failures": rows, "counts": dict(Counter(r["kind"] for r in rows))}
+
+
+def main(argv: list[str] | None = None) -> int:
+    ap = argparse.ArgumentParser(description=__doc__.split("\n\n")[0])
+    ap.add_argument("dsn", type=Path)
+    ap.add_argument("--edge-clearance", type=float, metavar="MM")
+    ap.add_argument("--grid-resolution", type=int, default=2, metavar="K")
+    ap.add_argument("--shove", action="store_true", help="as mckicad routes")
+    ap.add_argument("--access-cost", type=float, default=0.0)
+    ap.add_argument("--json", type=Path, help="also write the full table here")
+    args = ap.parse_args(argv)
+
+    report = diagnose(args.dsn.read_text(), args.edge_clearance, args.grid_resolution, args.shove,
+                      args.access_cost)
+    for row in report["failures"]:
+        extra = ""
+        for w in row.get("walled", []):
+            extra += f"  [{w['pin']} reaches {w['reach']} cells, walled by {', '.join(w['walls'])}]"
+        if "conflict" in row:
+            c = row["conflict"]
+            extra += (f"  [{c['copper']} on layer {c['layer']} {c['short_mm']} mm too close"
+                      f" to {c['against']}]")
+        print(f"{row['kind']:11} {row['net']}: {row['a']} to {row['b']}{extra}")
+    total = sum(report["counts"].values())
+    print(f"\n{total} failed: " + ", ".join(f"{k} {v}" for k, v in sorted(report["counts"].items())),
+          file=sys.stderr)
+    if args.json:
+        args.json.write_text(json.dumps(report, indent=1))
+    return 0
+
+
+if __name__ == "__main__":
+    raise SystemExit(main())

src/freeroute/cli.py

@@ -19,7 +19,7 @@ import argparse
 import sys
 
 from freeroute.dsn.reader import parse_dsn
-from freeroute.route.orders import best_of_orders
+from freeroute.route.orders import best_of_orders, promote_failures
 from freeroute.route.pipeline import (
     build_exact_routing_result,
     build_rooms_routing_result,
@@ -30,8 +30,8 @@ from freeroute.ses import write_ses
 #: which optional flags each engine actually implements. Anything not listed for
 #: an engine is rejected by :func:`_validate` rather than quietly ignored.
 ENGINE_OPTIONS: dict[str, frozenset[str]] = {
-    "grid": frozenset({"rip_up", "max_passes", "seed", "orders"}),
-    "exact": frozenset({"shove", "diagonal", "rip_up", "max_passes", "seed", "orders"}),
+    "grid": frozenset({"rip_up", "max_passes", "seed", "orders", "promote", "access"}),
+    "exact": frozenset({"shove", "diagonal", "rip_up", "max_passes", "seed", "orders", "promote", "access"}),
     "room": frozenset({"shove", "pack"}),
 }
 
@@ -44,6 +44,8 @@ _FLAG_NAMES = {
     "max_passes": "-mp/--max-passes",
     "seed": "--seed",
     "orders": "--orders",
+    "promote": "--promote-failures",
+    "access": "--access-cost",
 }
 
 
@@ -150,6 +152,20 @@ def build_parser() -> argparse.ArgumentParser:
         help="grid and exact engines: route N connection orders in parallel and keep the "
         "one leaving the fewest connections unrouted (the default order is one of them)",
     )
+    parser.add_argument(
+        "--promote-failures",
+        type=int,
+        metavar="R",
+        help="grid and exact engines: up to R rounds, each routing the connections that "
+        "failed so far first; keeps the best round",
+    )
+    parser.add_argument(
+        "--access-cost",
+        type=float,
+        metavar="C",
+        help="grid and exact engines: extra cost for a route to pass where it would close "
+        "another pin's way out while that pin still has connections to route (default 0: off)",
+    )
     parser.add_argument(
         "--jobs",
         type=int,
@@ -177,6 +193,8 @@ def main(argv: list[str] | None = None) -> int:
             ("max_passes", args.max_passes is not None),
             ("seed", args.seed is not None),
             ("orders", args.orders is not None),
+            ("promote", args.promote_failures is not None),
+            ("access", args.access_cost is not None),
         )
         if asked
     ]
@@ -210,6 +228,7 @@ def main(argv: list[str] | None = None) -> int:
             "edge_clearance_mm": args.edge_clearance,
             "resolution": 2 if args.grid_resolution is None else args.grid_resolution,
             "heuristic_weight": args.heuristic_weight,
+            "access_cost": args.access_cost or 0.0,
         }
     elif args.engine == "grid":
         options = {
@@ -218,12 +237,21 @@ def main(argv: list[str] | None = None) -> int:
             "max_passes": max_passes,
             "edge_clearance_mm": args.edge_clearance,
             "resolution": 1 if args.grid_resolution is None else args.grid_resolution,
+            "access_cost": args.access_cost or 0.0,
         }
     if args.engine == "room":
         result = build_rooms_routing_result(
             dsn, layers=layers, shove=args.shove, pack=args.pack,
             edge_clearance_mm=args.edge_clearance,
         )
+    elif args.promote_failures and args.promote_failures > 1:
+        if args.orders:
+            parser.error("--orders and --promote-failures cannot be combined")
+        result, rounds = promote_failures(
+            dsn_text, args.engine, options, rounds=args.promote_failures, seed=args.seed
+        )
+        counts = ", ".join(str(m) for m, _z in rounds)
+        print(f"freeroute: {len(rounds)} rounds, unrouted {counts}; kept the best", file=sys.stderr)
     elif args.orders and args.orders > 1:
         result, kept, tried = best_of_orders(
             dsn_text, args.engine, options, orders=args.orders, seed=args.seed, jobs=args.jobs

src/freeroute/route/exact_router.py

@@ -95,6 +95,8 @@ def route_board_exact(
     resolution: int = 1,
     heuristic_weight: float = 1.0,
     seed: int | None = None,
+    route_first: frozenset | None = None,
+    access_cost: float = 0.0,
 ) -> ExactRouteResult:
     """Route ``board`` orthogonally and verify the result with exact geometry.
 
@@ -124,6 +126,8 @@ def route_board_exact(
         resolution=resolution,
         heuristic_weight=heuristic_weight,
         seed=seed,
+        route_first=route_first,
+        access_cost=access_cost,
     )
     edge = 0 if edge_clearance is None else edge_clearance
     outline = board.outline

src/freeroute/route/grid_router.py

@@ -156,11 +156,22 @@ class GridRouter:
         resolution: int = 1,
         heuristic_weight: float = 1.0,
         seed: int | None = None,
+        route_first: frozenset | None = None,
+        access_cost: float = 0.0,
     ) -> None:
         self.board = board
+        # Pin access: while a pin still has connections to route, the cells
+        # its route would leave by (its end cells, the via it may need there,
+        # and the clearance around both) cost other nets this much extra, so
+        # they route round a fine-pitch pin's way out instead of sealing it.
+        self.access_cost = max(float(access_cost), 0.0)
+        self._doorways: dict[Node, list[tuple[int, int]]] = {}
+        self._pending: dict[int, int] = {}
         # None keeps the deterministic order; a seed shuffles which connection
         # routes first, to measure how much a result owes to the order
         self.seed = seed
+        # connections, as (net_no, one end, other end), to route before the rest
+        self.route_first = frozenset(route_first or ())
         # how far (in cells) an escape stub may run to leave a walled-in pin
         self._escape_cells = 12
         self._crowded_cache: dict = {}
@@ -286,6 +297,8 @@ class GridRouter:
         margin = self.clearance + self.half_width
         outline = self.board.outline
         self._via_edge_block: set[Cell] = set()
+        # wire keepouts as boxes, to check a pin stub the way the exact engine will
+        self._keepout_boxes: dict[int, list[IntBox]] = {}
         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
@@ -322,6 +335,8 @@ class GridRouter:
                     if box.is_empty():
                         continue
                     # the same distance the exact engine verifies against
+                    if item.blocks_wires:
+                        self._keepout_boxes.setdefault(item.layer, []).append(box)
                     for cell in self._cells_in_box(box, margin):
                         if item.blocks_wires:
                             self._keepout.add((*cell, item.layer))
@@ -471,12 +486,16 @@ class GridRouter:
                     enter = self._enter_cost(cell, cl, net_no, allow_ripup, conns)
                     if enter is None:
                         continue
+                    if self._doorways:
+                        enter += self._access(nxt, net_no)
                 step = 1.0 if dx == 0 or dy == 0 else math.sqrt(2)
                 self._relax(
                     current, nxt, base + step + enter, goal_cell, g_score, came_from, open_heap
                 )
             if len(self.layers) > 1:
                 g_via = base + self.via_cost
+                if self._doorways:
+                    g_via += self._access(current, net_no)
                 for layer in self.layers:
                     if layer == cl:
                         continue
@@ -510,6 +529,18 @@ class GridRouter:
         ]
 
     def _stub_clear(self, pin: Pin, cell: Cell, layer: int, net_no: int, conns) -> bool:
+        keepouts = self._keepout_boxes.get(layer)
+        if keepouts:
+            # the stub is off the grid, so check it exactly, as the exact
+            # engine will: its copper grown by clearance must miss every keepout
+            from freeroute.geometry.polyline import Polyline, PolylineShape
+
+            end = self._cell_center(cell)
+            if end != pin.location:
+                for tile in PolylineShape(Polyline([pin.location, end]), self.half_width).tiles():
+                    grown = tile.offset(self.clearance)
+                    if any(k.overlaps(grown) for k in keepouts):
+                        return False
         for c in self._stub_cells(pin.location, cell):
             owner = self._cell_owner.get((*c, layer))
             if owner is not None and conns[owner].net_no != net_no:
@@ -762,8 +793,19 @@ class GridRouter:
                 if node not in self._cell_owner:
                     self._cell_owner[node] = conn.index
                     conn.trace_cells.append((c, layer))
+        # A pin inside a wire keepout can only leave by a via. Its stub to the
+        # cell centre would be track inside the keepout, so the via goes on
+        # the pin itself (a via in its own pad) and the stub is left out.
+        in_pad: dict[int, IntPoint] = {}
+        if len(wire_segs) > 1:
+            for idx, pin in ((0, conn.a_end), (len(wire_segs) - 1, conn.b_end)):
+                layer, cells = wire_segs[idx]
+                if isinstance(pin, Pin) and len(cells) == 1 and (*cells[0], layer) in self._keepout:
+                    in_pad[idx] = pin.location
         conn.wires = []
         for idx, (layer, cells) in enumerate(wire_segs):
+            if idx in in_pad:
+                continue
             points = [self._cell_center(c) for c in cells]
             if idx == 0 and isinstance(conn.a_end, Pin):
                 points.insert(0, conn.a_end.location)
@@ -773,7 +815,11 @@ class GridRouter:
             if len(points) >= 2:
                 conn.wires.append((layer, points))
         conn.vias = [self._cell_center(c) for c in conn.via_cells]
+        for idx, location in in_pad.items():
+            # via k joins wire segments k and k + 1
+            conn.vias[0 if idx == 0 else idx - 1] = location
         conn.routed = True
+        self._settle(conn, -1)
 
     def _rip(self, conn: _Connection) -> None:
         for cell, layer in conn.trace_cells:
@@ -796,6 +842,7 @@ class GridRouter:
         conn.vias = []
         conn.routed = False
         conn.rip_count += 1
+        self._settle(conn, +1)
 
     def _crossed_owners(self, path: list[Node], net_no: int, conns: list[_Connection]) -> set[int]:
         owners: set[int] = set()
@@ -811,6 +858,50 @@ class GridRouter:
                     owners.add(i)
         return owners
 
+    # --- pin access ---------------------------------------------------------
+
+    @staticmethod
+    def _group_pins(conn: _Connection):
+        return [*conn.a_group[0], *conn.b_group[0]]
+
+    def _build_doorways(self, conns: list[_Connection]) -> None:
+        """Map every cell that would close a pin's way out to that pin."""
+        spread = [(0, 0), *self._halo_offsets]
+        done: set[int] = set()
+        for conn in conns:
+            for pin in self._group_pins(conn):
+                self._pending[id(pin)] = self._pending.get(id(pin), 0) + 1
+                if id(pin) in done:
+                    continue
+                done.add(id(pin))
+                claim = (id(pin), conn.net_no)
+                exits: set[Node] = set()
+                for x, y, layer in self._end_nodes(pin, conn.net_no, conns):
+                    exits.add((x, y, layer))
+                    for c in self._via_cells((x, y)):
+                        exits.update((*c, other) for other in self.layers)
+                cells: set[Node] = set()
+                for x, y, layer in exits:
+                    for dx, dy in spread:
+                        if 0 <= x + dx < self.cols and 0 <= y + dy < self.rows:
+                            cells.add((x + dx, y + dy, layer))
+                for node in cells:
+                    self._doorways.setdefault(node, []).append(claim)
+
+    def _settle(self, conn: _Connection, delta: int) -> None:
+        if not self._pending:
+            return
+        for pin in self._group_pins(conn):
+            if id(pin) in self._pending:
+                self._pending[id(pin)] += delta
+
+    def _access(self, node: Node, net_no: int) -> float:
+        """Extra cost for ``net_no`` to use a cell another pin still needs."""
+        for pin_id, owner_net in self._doorways.get(node, ()):
+            if owner_net != net_no and self._pending.get(pin_id, 0) > 0:
+                return self.access_cost
+        return 0.0
+
     # --- passes -------------------------------------------------------------
 
     def route(self) -> RouteResult:
@@ -819,6 +910,8 @@ class GridRouter:
         self._conns = conns
         if not conns:
             return RouteResult(self.half_width)
+        if self.access_cost:
+            self._build_doorways(conns)
 
         passes = self.max_passes if self.rip_up else 1
         best_count = -1
@@ -828,6 +921,9 @@ class GridRouter:
         order = list(conns)
         if self.seed is not None:
             random.Random(self.seed).shuffle(order)
+        if self.route_first:
+            # stable: the promoted keep their order among themselves, as do the rest
+            order.sort(key=lambda c: (c.net_no, *_ends_of(c)) not in self.route_first)
         for _ in range(passes):
             changed = False
             for conn in order:
@@ -1060,6 +1156,8 @@ def route_board(
     resolution: int = 1,
     heuristic_weight: float = 1.0,
     seed: int | None = None,
+    route_first: frozenset | None = None,
+    access_cost: float = 0.0,
 ) -> RouteResult:
     """Convenience wrapper: build a :class:`GridRouter` and route the board."""
     router = GridRouter(
@@ -1076,5 +1174,7 @@ def route_board(
         resolution=resolution,
         heuristic_weight=heuristic_weight,
         seed=seed,
+        route_first=route_first,
+        access_cost=access_cost,
     )
     return router.route()

src/freeroute/route/orders.py

@@ -65,3 +65,34 @@ def best_of_orders(
     scores = [score(r) for r in results]
     best = min(range(len(seeds)), key=lambda i: (scores[i], i))
     return results[best], seeds[best], list(zip(seeds, scores, strict=True))
+
+
+def promote_failures(
+    dsn_text: str,
+    engine: str,
+    options: dict,
+    *,
+    rounds: int,
+    seed: int | None = None,
+) -> tuple[RoutingResult, list[tuple[int, int]]]:
+    """Route, then route again with every connection that has failed so far
+    moved to the front, keeping the rest in their order. Returns the best
+    round's result and every round's score.
+
+    The promoted set only grows, so a connection that failed once keeps its
+    early place and two groups cannot take turns failing. Stops early when a
+    round routes everything or fails nothing new."""
+    numbers = {n.name: i + 1 for i, n in enumerate(parse_dsn(dsn_text).nets)}
+    first: frozenset = frozenset()
+    best: RoutingResult | None = None
+    scores: list[tuple[int, int]] = []
+    for _ in range(max(int(rounds), 1)):
+        result = route_once(dsn_text, engine, {**options, "route_first": first}, seed)
+        scores.append(score(result))
+        if best is None or scores[-1] < score(best):
+            best = result
+        failed = {(numbers.get(name), a, b) for name, a, b, zone in result.unrouted if not zone}
+        if not failed or failed <= first:
+            break
+        first = first | failed
+    return best, scores

src/freeroute/route/pipeline.py

@@ -81,6 +81,8 @@ def route_dsn_board(
     rip_up: bool = True,
     max_passes: int = 10,
     seed: int | None = None,
+    route_first: frozenset | None = None,
+    access_cost: float = 0.0,
 ) -> tuple[RouteResult, int, list[str]]:
     """Route a parsed :class:`DsnBoard`; return the board-unit result, the scale,
     and the layer names. ``layers`` restricts routing to those signal-layer
@@ -102,6 +104,8 @@ def route_dsn_board(
         rip_up=rip_up,
         max_passes=max_passes,
         seed=seed,
+        route_first=route_first,
+        access_cost=access_cost,
     )
     return result, scale, [layer.name for layer in dsn.layers]
 
@@ -143,11 +147,15 @@ def build_routing_result(
     max_passes: int = 10,
     edge_clearance_mm: float | None = None,
     seed: int | None = None,
+    route_first: frozenset | None = None,
+    access_cost: float = 0.0,
 ) -> 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,
         edge_clearance_mm=edge_clearance_mm, resolution=resolution, seed=seed,
+        route_first=route_first,
+        access_cost=access_cost,
     )
     return _to_routing_result(route, dsn, scale, layer_names)
 
@@ -164,6 +172,8 @@ def route_dsn_board_exact(
     shove: bool = False,
     diagonal: bool = False,
     seed: int | None = None,
+    route_first: frozenset | None = None,
+    access_cost: float = 0.0,
 ) -> tuple[ExactRouteResult, int, list[str]]:
     """Route a parsed :class:`DsnBoard` with the exact-geometry (orthogonal,
     DRC-verified) track; return the exact result, the scale, and layer names.
@@ -189,6 +199,8 @@ def route_dsn_board_exact(
         shove=shove,
         diagonal=diagonal,
         seed=seed,
+        route_first=route_first,
+        access_cost=access_cost,
     )
     return exact, scale, [layer.name for layer in dsn.layers]
 
@@ -205,6 +217,8 @@ def build_exact_routing_result(
     max_passes: int = 10,
     edge_clearance_mm: float | None = None,
     seed: int | None = None,
+    route_first: frozenset | None = None,
+    access_cost: float = 0.0,
 ) -> RoutingResult:
     """Route ``dsn`` (exact track) and convert to a DSN-unit RoutingResult."""
     exact, scale, layer_names = route_dsn_board_exact(
@@ -218,6 +232,8 @@ def build_exact_routing_result(
         resolution=resolution,
         heuristic_weight=heuristic_weight,
         seed=seed,
+        route_first=route_first,
+        access_cost=access_cost,
     )
     return _to_routing_result(exact.result, dsn, scale, layer_names)
 

tests/route/test_orders.py

@@ -5,7 +5,13 @@ from __future__ import annotations
 from pathlib import Path
 
 from freeroute.cli import main
-from freeroute.route.orders import best_of_orders, candidate_seeds, route_once, score
+from freeroute.route.orders import (
+    best_of_orders,
+    candidate_seeds,
+    promote_failures,
+    route_once,
+    score,
+)
 
 FIXTURES = Path(__file__).resolve().parent.parent / "dsn" / "fixtures"
 # Greedy (no rip-up), the default order strands a net here and seeds 1 to 3 do not.
@@ -42,3 +48,31 @@ def test_cli_orders_writes_the_best_session(tmp_path, capsys):
     assert "tried 3 orders, kept --seed 1" in err
     assert "not routed" not in err
     assert out.read_text().startswith("(session")
+
+
+def test_promoting_the_failed_connection_routes_it():
+    best, rounds = promote_failures(RIPUP, "grid", GREEDY, rounds=3)
+    assert rounds == [(1, 0), (0, 0)]  # stops once nothing fails
+    assert score(best) == (0, 0)
+
+
+def test_nothing_promoted_is_the_plain_order():
+    plain = route_once(RIPUP, "grid", {}, None)
+    empty = route_once(RIPUP, "grid", {"route_first": frozenset()}, None)
+    assert plain == empty
+
+
+def test_cli_promote_failures(tmp_path, capsys):
+    out = tmp_path / "p.ses"
+    rc = main(
+        [
+            str(FIXTURES / "ripup_needed.dsn"),
+            "--no-rip-up",
+            "--promote-failures",
+            "3",
+            "-do",
+            str(out),
+        ]
+    )
+    assert rc == 0
+    assert "2 rounds, unrouted 1, 0" in capsys.readouterr().err

tests/test_cli.py

@@ -156,6 +156,8 @@ def test_cli_supported_combinations_are_accepted(tmp_path):
         "max_passes": ["-mp", "4"],
         "seed": ["--seed", "3"],
         "orders": ["--orders", "2"],
+        "promote": ["--promote-failures", "2"],
+        "access": ["--access-cost", "5"],
     }
     for engine, options in ENGINE_OPTIONS.items():
         for option in options: