Window boards: never search a connection ending outside the window

With items away from the window left off its board, a stub from the window
edge out to a rerouted net's far pin crossed copper the exact check never
saw: 38 shorts on th-eda's flight controller. A connection with an end
outside the bounds is now left unrouted, and a window whose new copper
leaves the window is refused.

.gitignore

@@ -20,3 +20,7 @@ htmlcov/
 # Editor / OS
 .DS_Store
 *.swp
+
+# Benchmark inputs and results: board lists name local, often private, designs
+/bench/boards*.txt
+/bench/results/

README.md

@@ -1,6 +1,6 @@
 # freeroute
 
-A native Python PCB autorouter — a Java-free reimplementation of the
+A native Python PCB autorouter: a Java-free reimplementation of the
 [FreeRouting](https://github.com/freerouting/freerouting) engine. Specctra DSN
 in, Specctra SES out, no JVM anywhere in the pipeline.
 
@@ -8,8 +8,8 @@ in, Specctra SES out, no JVM anywhere in the pipeline.
 
 Toolchains that autoroute (`kicad-mcp` among them) do it by shelling out to
 `freerouting.jar`, which drags a JVM into every install and container image.
-`freeroute` reimplements the routing engine in pure Python — no dependencies at
-all, standard library only — so the JAR step becomes a `pip install`.
+`freeroute` reimplements the routing engine in pure Python, with no dependencies
+beyond the standard library, so the JAR step becomes a `pip install`.
 
 ## The contract
 
@@ -21,7 +21,7 @@ board.dsn  ──▶  freeroute  ──▶  board.ses
 ```
 
 `kicad-cli` already exports `.dsn` and imports `.ses`, so `freeroute` drops in
-wherever `java -jar freerouting.jar` was invoked — nothing else in the pipeline
+wherever `java -jar freerouting.jar` was invoked, and nothing else in the pipeline
 changes. The `-de` / `-do` / `-mp` flags are the JAR's, on purpose.
 
 ## Install
@@ -33,27 +33,31 @@ uv tool install freeroute      # or: pipx install freeroute
 ## Usage
 
 ```bash
-freeroute board.dsn -o board.ses          # grid engine, the default
-freeroute -de board.dsn -do board.ses     # the FreeRouting JAR spelling
+# a KiCad board: the exact engine, with the board's copper-to-edge rule
+freeroute board.dsn --engine exact --shove --edge-clearance 0.5 -do board.ses
 
+freeroute -de board.dsn -do board.ses     # the FreeRouting JAR spelling (grid engine)
 freeroute board.dsn --engine room --pack --shove -do board.ses
-freeroute board.dsn --engine exact --diagonal --shove -do board.ses
 ```
 
-With no `-do` / `-o`, the SES goes to stdout.
+With no `-do` / `-o`, the SES goes to stdout. Connections freeroute could not
+make are listed on stderr; the SES is still written and the exit code stays 0,
+as with the JAR. Connections whose two ends sit in one zone of their net are
+listed separately, as left to that zone's fill.
 
 ### Engines
 
 Three routing tracks, selected with `--engine`:
 
-- **`grid`** (default) — multi-layer maze router over a uniform occupancy grid,
-  with rip-up-and-retry and via search. Highest raw connectivity of the three;
-  its geometry is grid-quantised, so it is the least precise about clearance.
-- **`exact`** — orthogonal router whose output is verified against exact integer
-  geometry (tile/octagon clearance, not bounding boxes). Cleaner, DRC-clean
-  output where it succeeds; it will drop a net rather than emit a violation.
-- **`room`** — continuous expansion-room router: an exact decomposition of free
-  space, so it routes off-grid channels that the grid quantisation cannot see.
+- **`exact`** (recommended for real boards): orthogonal grid search whose every
+  accepted connection is verified against exact integer geometry. It drops a
+  connection rather than emit a violation. Defaults to `--grid-resolution 2`.
+- **`grid`** (the default, for JAR-compatible invocation): the same multi-layer
+  maze router with rip-up and via search, without the exact check, so its
+  geometry is only as precise as the grid.
+- **`room`**: continuous expansion-room router, an exact decomposition of free
+  space. It routes off-grid channels the grid cannot see, but it is much slower
+  on real boards and does not yet use zones.
 
 ### Flags
 
@@ -62,6 +66,9 @@ Three routing tracks, selected with `--engine`:
 | `--engine {grid,exact,room}` | routing track (default: `grid`) |
 | `-de`, `--design` | input `.dsn` (FreeRouting-compatible alias) |
 | `-do`, `--output` | output `.ses` (default: stdout) |
+| `--edge-clearance MM` | copper to board-edge clearance, e.g. KiCad's `min_copper_edge_clearance`, which the DSN does not carry (default 0: copper only has to stay inside the outline) |
+| `--grid-resolution K` | grid cells K times finer than trace + clearance (default 2 for exact, 1 for grid); finer reaches fine-pitch pins at a cost in time |
+| `--heuristic-weight W` | exact: weighted A*, routes at most W times the shortest (default 1) |
 | `-mp`, `--max-passes` | rip-up-and-retry pass bound (default 10) |
 | `--no-rip-up` | single greedy pass, no rip-up |
 | `--layers` | comma-separated signal layer indices to route on |
@@ -74,65 +81,90 @@ unsupported combination is a hard error (exit 2) rather than a silent no-op:
 
 | | `--pack` | `--shove` | `--diagonal` | `--no-rip-up` | `-mp` |
 |---|---|---|---|---|---|
-| **grid** | — | — | — | yes | yes |
-| **exact** | — | yes | yes | yes | yes |
-| **room** | yes | yes | — | — | — |
+| **grid** | no | no | no | yes | yes |
+| **exact** | no | yes | yes | yes | yes |
+| **room** | yes | yes | no | no | no |
 
-`--layers` works on all three.
+`--layers` and `--edge-clearance` work on all three; `--grid-resolution` on grid
+and exact.
 
 What the opt-in passes buy you:
 
-- **`--pack`** (room) — when several 2-pin nets have to cross the same obstacle
-  gap, they are assigned consistent parallel lanes and routed together, so a
-  channel physically wide enough for all of them stops dropping nets to greedy
-  per-net gate collisions.
-- **`--shove`** (exact, room) — a net that would be dropped nudges the blocking
+- **`--pack`** (room): when several 2-pin nets have to cross the same obstacle
+  gap, they are assigned consistent parallel lanes and routed together.
+- **`--shove`** (exact, room): a net that would be dropped nudges the blocking
   committed traces aside and re-routes, rolling every moved trace back if the
-  retry fails. On the room engine it also turns on occupancy-aware gate
-  placement. It recovers *ordering* drops; it cannot manufacture space that is
-  not there.
-- **`--diagonal`** (exact) — a still-dropped 2-pin net is retried as a 45° trace
-  whose diagonal copper is covered by an exact integer octagon, so it fits
-  corridors the orthogonal L cannot, at the ideal hypotenuse length.
+  retry fails. It recovers *ordering* drops; it cannot make space that is not
+  there.
+- **`--diagonal`** (exact): a still-dropped 2-pin net is retried as a 45° trace
+  covered by an exact integer octagon.
+
+## What freeroute reads from a KiCad DSN
+
+These were each checked against KiCad itself, pad by pad or with its DRC:
+
+- **Pads** placed as KiCad places them: back-side parts on the mirrored copper
+  layer, outlines rotated with the part, oval pads at their full width, the
+  largest shape of a multi-layer padstack.
+- **Vias** at the size of the DSN's via padstack.
+- **Keepouts**: `keepout` blocks tracks and vias, `wire_keepout` (KiCad's "no
+  tracks" rule area) tracks only, `via_keepout` vias only; a rule area with a
+  hole (a no-track ring along the edge) is split into convex pieces rather than
+  filled in; footprint-level keepouts (a mounting hole's plated ring) are placed
+  with their part; `place_keepout` does not affect routing.
+- **The real board outline**, rounded corners included, with `--edge-clearance`.
+- **Copper zones** (`plane`): a pad inside a zone connects through it, and a
+  route can end on it with a via. A zone is only counted on to connect when a
+  no-tracks rule area covers it; a board-wide pour can be split into islands by
+  other nets' tracks, so its pads are routed with tracks instead.
+- **Fine-pitch pins**: a finer grid, and exact escape stubs for pins the grid
+  cannot reach.
+
+SES coordinates are written in resolution units, exactly as the JAR writes them.
 
 ## Library use
 
 ```python
 from freeroute.route import route
 
-ses_text = route(dsn_text, engine="room", shove=True, pack=True)
+ses_text = route(dsn_text, engine="exact", shove=True, edge_clearance_mm=0.5)
 ```
 
 ## Status and honest scope
 
-Alpha, version 0.1.0. It parses real `kicad-cli` DSN output, routes, and writes
-SES that KiCad imports. What is actually implemented:
+Alpha. Measured on two real KiCad 10 boards (the TerraHawk charge node's power
+stage and sense board, 2026-09-27), with every track stripped, then routed, then
+checked with `kicad-cli pcb drc --refill-zones`:
 
-- Specctra DSN parser (structure, library, placement, network, rules, keepouts)
-  and SES writer.
-- Multi-layer routing with via search and rip-up-and-retry.
-- Exact integer geometry (tiles, octagons) with a spatial index, so the `exact`
-  and `room` engines verify their own output is clearance-clean.
-- Continuous expansion-room free-space decomposition.
-- Channel packing, shove, and 45° routing as described above.
+| board | freeroute exact | FreeRouting JAR | DRC errors from freeroute |
+|---|---|---|---|
+| power stage (40 x 30 mm) | 7 unconnected, ~5 s | 12 | 0 |
+| sense board (55 x 25 mm, 0.5 mm pitch MCU) | 41 unconnected, ~2.5 min | 32 | 0 |
+
+In the board owner's production flow (hand-routed power lanes kept, pours added
+after routing), freeroute completed the power stage with no unconnected items.
 
 What it is **not**, stated plainly:
 
-- **Not at FreeRouting/JAR density parity on dense commercial boards.** The JAR
-  remains the better router when the board is hard. `freeroute` is honest about
-  drops: it leaves a net unrouted rather than emit a DRC violation, so on a
-  crowded board expect fewer completed nets than the JAR would manage.
-- **`--diagonal` is a shortening/recovery pass, not diagonal-native search.**
-  The maze search is orthogonal; 45° geometry is applied to nets the orthogonal
-  pass dropped or to shorten a staircase. A true 45°-native expansion-room maze
-  is not implemented.
-- No fanout pass, no post-route optimiser, no interactive/incremental routing,
-  no net classes with per-class widths beyond the default rules, no plane/pour
-  handling.
+- **Not yet at JAR completion on a dense board.** The legality of what it routes
+  holds up; how much it routes does not match the JAR yet. The remaining gap is
+  congestion: routes committed one at a time block later ones. The JAR's
+  negotiated rip-up loop handles that better. Negotiated congestion routing is
+  the planned next step.
+- **Slower than the JAR** on a dense board (minutes against seconds), being
+  pure Python.
+- **`--diagonal` is a recovery pass, not diagonal-native search.**
+- The `room` engine does not use zones, the outline edge rule is only enforced
+  approximately there, and it is slow on real boards.
+- No fanout pass, no post-route optimiser, no incremental routing, no per-class
+  track widths beyond the default rules.
+- Copper that KiCad draws as graphics (a net tie's polygon, a logo) is not in
+  the DSN at all, so no router sees it; mckicad adds footprint copper to the DSN
+  as keepouts.
 
-If you need maximum completion on a dense board today, use the JAR. If you need
-routing without a JVM — CI, containers, an MCP server, a library call — this is
-that.
+For maximum completion on a dense board today, the JAR is still the stronger
+router. For routing without a JVM (CI, containers, an MCP server, a library
+call), freeroute routes legally and says what it could not do.
 
 ## Development
 
@@ -144,7 +176,7 @@ uv run ruff check src/ tests/
 
 The `oracle`-marked tests run the real `freerouting.jar` as a differential
 reference and skip cleanly when Java or the JAR is absent. The JAR is never
-vendored, and neither is the upstream Java source — see
+vendored, and neither is the upstream Java source; see
 [`docs/ARCHITECTURE.md`](docs/ARCHITECTURE.md) for the port map and
 [`docs/PORTING_PLAN.md`](docs/PORTING_PLAN.md) for the roadmap.
 

bench/bench.py

@@ -0,0 +1,206 @@
+"""Route boards under several connection orders and compare variants fairly.
+
+One routing run says little: which connection routes first moves a result by
+ten connections either way on a crowded board. This runs every board with
+every variant under the same seeds (``--seed``), so variant A and variant B
+face the same order on seed 3, and compares them seed by seed.
+
+    uv run python bench/bench.py BOARDS -v base= -v hist1="--history-cost 1" \\
+        --seeds 6 --jobs 4 --out bench/results/hist.jsonl
+
+BOARDS is a text file, one board per line: a name, a DSN path and any flags
+that board always needs, e.g.
+
+    sense  /path/to/charge-sense.dsn  --edge-clearance 0.5
+    # comments and blank lines are ignored
+
+A variant is ``NAME=FLAGS``, or ``NAME@SRC=FLAGS`` to run the code under SRC
+(a worktree's ``src`` directory) rather than the installed package. The first
+variant is the baseline. Results are appended to --out as JSON lines, and runs
+already in it are skipped, so an interrupted benchmark picks up where it left
+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
+import sys
+import tempfile
+import threading
+import time
+
+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")
+
+
+def parse_boards(path: Path) -> list[tuple[str, Path, list[str]]]:
+    boards = []
+    for line in path.read_text().splitlines():
+        words = shlex.split(line, comments=True)
+        if not words:
+            continue
+        if len(words) < 2:
+            raise SystemExit(f"{path}: want 'name path [flags]', got {line!r}")
+        dsn = Path(words[1]).expanduser()
+        if not dsn.is_file():
+            raise SystemExit(f"{path}: no such DSN {dsn}")
+        boards.append((words[0], dsn, words[2:]))
+    return boards
+
+
+def parse_variant(spec: str) -> tuple[str, str | None, list[str]]:
+    head, sep, flags = spec.partition("=")
+    if not sep or not head:
+        raise SystemExit(f"variant {spec!r}: want NAME=FLAGS or NAME@SRC=FLAGS")
+    name, _, src = head.partition("@")
+    if src and not (Path(src) / "freeroute").is_dir():
+        raise SystemExit(f"variant {name}: {src} has no freeroute package")
+    return name, src or None, shlex.split(flags)
+
+
+def run_one(board, variant, seed: int, timeout: float) -> dict:
+    name, dsn, board_flags = board
+    vname, src, flags = variant
+    env = dict(os.environ)
+    if src:
+        env["PYTHONPATH"] = src + os.pathsep + env.get("PYTHONPATH", "")
+    with tempfile.TemporaryDirectory() as tmp:
+        cmd = [
+            sys.executable, "-m", "freeroute.cli", str(dsn), "-do", f"{tmp}/out.ses",
+            *board_flags, *flags, "--seed", str(seed),
+        ]
+        start = time.monotonic()
+        proc = subprocess.Popen(
+            cmd, env=env, stdout=subprocess.DEVNULL, stderr=subprocess.PIPE, text=True
+        )
+        expired = threading.Event()
+
+        def expire() -> None:
+            expired.set()
+            proc.kill()
+
+        timer = threading.Timer(timeout, expire)
+        timer.start()
+        err = proc.stderr.read()
+        # reap it here rather than through Popen, to keep its peak memory
+        _, wstatus, usage = os.wait4(proc.pid, 0)
+        timer.cancel()
+        proc.returncode = os.waitstatus_to_exitcode(wstatus)
+        proc.stderr.close()
+        status = "timeout" if expired.is_set() else (
+            "ok" if proc.returncode == 0 else f"exit {proc.returncode}"
+        )
+        rss_mb = round(usage.ru_maxrss / 1024)
+        secs = round(time.monotonic() - start, 1)
+    missing = NOT_ROUTED.search(err)
+    zone = TO_ZONE.search(err)
+    return {
+        "board": name, "variant": vname, "seed": seed, "status": status,
+        "unrouted": int(missing.group(1)) if missing else 0,
+        "to_zone": int(zone.group(1)) if zone else 0,
+        "secs": secs, "rss_mb": rss_mb,
+        "tail": err.strip().splitlines()[-1] if status != "ok" and err.strip() else "",
+    }
+
+
+def mean_sd(xs: list[float]) -> tuple[float, float]:
+    m = sum(xs) / len(xs)
+    sd = math.sqrt(sum((x - m) ** 2 for x in xs) / (len(xs) - 1)) if len(xs) > 1 else 0.0
+    return m, sd
+
+
+def report(rows: list[dict], boards, variants) -> None:
+    ok = {(r["board"], r["variant"], r["seed"]): r for r in rows if r["status"] == "ok"}
+    base = variants[0][0]
+    print(f"\nunrouted per board (lower is better), baseline {base!r}\n")
+    print(f"{'board':14} {'variant':14} {'n':>3} {'mean':>6} {'sd':>5} {'min':>4} {'max':>4}"
+          f" {'secs':>6}   vs baseline, seed by seed")
+    for bname, _, _ in boards:
+        for vname, _, _ in variants:
+            runs = sorted((k[2], r) for k, r in ok.items() if k[:2] == (bname, vname))
+            if not runs:
+                print(f"{bname:14} {vname:14}   no finished runs")
+                continue
+            xs = [r["unrouted"] for _, r in runs]
+            m, sd = mean_sd(xs)
+            t, _ = mean_sd([r["secs"] for _, r in runs])
+            line = (f"{bname:14} {vname:14} {len(xs):>3} {m:>6.1f} {sd:>5.1f} {min(xs):>4}"
+                    f" {max(xs):>4} {t:>6.0f}")
+            if vname != base:
+                diffs = [r["unrouted"] - ok[(bname, base, s)]["unrouted"]
+                         for s, r in runs if (bname, base, s) in ok]
+                if diffs:
+                    dm, dsd = mean_sd(diffs)
+                    se = dsd / math.sqrt(len(diffs)) if len(diffs) > 1 else float("inf")
+                    better = sum(d < 0 for d in diffs)
+                    worse = sum(d > 0 for d in diffs)
+                    # a difference inside two standard errors is not a finding
+                    verdict = ("better" if dm < 0 else "worse") if abs(dm) > 2 * se else "no clear change"
+                    line += (f"   {dm:+.1f} ± {se:.1f}  ({better} better, {worse} worse,"
+                             f" {len(diffs) - better - worse} same)  {verdict}")
+            print(line)
+    failed = [r for r in rows if r["status"] != "ok"]
+    for r in failed:
+        print(f"FAILED {r['board']} {r['variant']} seed {r['seed']}: {r['status']} {r['tail']}")
+
+
+def main(argv: list[str] | None = None) -> int:
+    ap = argparse.ArgumentParser(description=__doc__.split("\n\n")[0])
+    ap.add_argument("boards", type=Path, help="board list: name, DSN path, flags")
+    ap.add_argument("-v", "--variant", action="append", required=True,
+                    help="NAME=FLAGS or NAME@SRC=FLAGS; the first is the baseline")
+    ap.add_argument("--seeds", type=int, default=6, help="orders per board and variant")
+    ap.add_argument("--first-seed", type=int, default=0)
+    ap.add_argument("--jobs", type=int, default=4, help="runs at once")
+    ap.add_argument("--timeout", type=float, default=1800, help="seconds per run")
+    ap.add_argument("--out", type=Path, required=True, help="JSON lines, appended")
+    ap.add_argument("--report-only", action="store_true", help="summarise --out, run nothing")
+    args = ap.parse_args(argv)
+
+    boards = parse_boards(args.boards)
+    variants = [parse_variant(v) for v in args.variant]
+    if len({v[0] for v in variants}) != len(variants):
+        raise SystemExit("variant names must differ")
+    seeds = range(args.first_seed, args.first_seed + args.seeds)
+
+    rows: list[dict] = []
+    if args.out.exists():
+        rows = [json.loads(line) for line in args.out.read_text().splitlines() if line.strip()]
+    done = {(r["board"], r["variant"], r["seed"]) for r in rows if r["status"] == "ok"}
+    todo = [(b, v, s) for b in boards for v in variants for s in seeds
+            if (b[0], v[0], s) not in done]
+
+    if not args.report_only and todo:
+        args.out.parent.mkdir(parents=True, exist_ok=True)
+        print(f"{len(todo)} runs, {args.jobs} at a time", file=sys.stderr)
+        # retried runs replace their earlier failure
+        rows = [r for r in rows if (r["board"], r["variant"], r["seed"]) in done]
+        with ThreadPoolExecutor(args.jobs) as pool, args.out.open("w") as out:
+            for r in rows:
+                out.write(json.dumps(r) + "\n")
+            futures = [pool.submit(run_one, b, v, s, args.timeout) for b, v, s in todo]
+            for n, fut in enumerate(as_completed(futures), 1):
+                r = fut.result()
+                rows.append(r)
+                out.write(json.dumps(r) + "\n")
+                out.flush()
+                print(f"[{n}/{len(todo)}] {r['board']} {r['variant']} seed {r['seed']}:"
+                      f" {r['status']} unrouted {r['unrouted']} ({r['secs']}s,"
+                      f" {r['rss_mb']} MB)", file=sys.stderr)
+
+    wanted = {(b[0], v[0], s) for b in boards for v in variants for s in seeds}
+    rows = [r for r in rows if (r["board"], r["variant"], r["seed"]) in wanted]
+    report(rows, boards, variants)
+    return 1 if any(r["status"] != "ok" for r in rows) or len(rows) < len(wanted) else 0
+
+
+if __name__ == "__main__":
+    raise SystemExit(main())

bench/diagnose.py

@@ -0,0 +1,310 @@
+"""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.geometry.octagon import overlaps_2d
+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,
+    _net_widths_board,
+    _rule_clearance_dsn,
+    _rule_width_dsn,
+    _via_drill_board,
+    _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:
+            # the shape that tripped the check, found the way the check does
+            other = None
+            expanded = box.offset(clearance)
+            for s in self.overlapping(expanded):
+                if s.net_no == net_no or not s.on_layer(layer):
+                    continue
+                if s.blocks != "all" and s.blocks != kind + "s":
+                    continue
+                if not s.clearance:
+                    if s.tile.overlaps(box):
+                        other = s
+                        break
+                    continue
+                if (s.exact is not None and overlaps_2d(s.exact, expanded)) or (
+                    s.exact is None and s.tile.overlaps(expanded)
+                ):
+                    other = s
+                    break
+            log.append((net_no, kind, layer, box, clearance, other))
+        return hit
+
+    ShapeSearchTree.clearance_conflict = conflict
+    return log
+
+
+def _wall_name(wall, names) -> str:
+    if isinstance(wall, str):
+        if wall.startswith("fixed copper of net "):
+            net = int(wall.rsplit(" ", 1)[1])
+            return f"fixed copper of {names.get(net, net)}"
+        return wall
+    return names.get(wall, "pads/keepouts")
+
+
+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 _static_wall(router: GridRouter, node) -> str:
+    """What static copper closes a node: a keepout, copper already on the
+    board (a fixed via or track, by net), or a pad."""
+    if node in router._keepout:
+        return "keepout"
+    fixed = getattr(router, "_diag_fixed", None)
+    if fixed is None:
+        fixed = router._diag_fixed = {}
+        margin = router.clearance + router.half_width
+        for net, layers, box in router.board.get_fixed_copper():
+            for cell in router._cells_in_box(box, margin):
+                for layer in layers:
+                    fixed[(*cell, layer)] = net
+    net = fixed.get(node)
+    if net is not None:
+        return f"fixed copper of net {net}"
+    return "pads"
+
+
+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[_static_wall(router, n)] += 1
+                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, hole_to_hole_mm: float = 0.25, seed: int | None = None,
+    negotiate: int = 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,
+        seed=seed,
+        negotiate=negotiate,
+        # the product's configuration: net-class widths and hole spacing
+        net_widths=_net_widths_board(dsn, scale),
+        via_drill=_via_drill_board(dsn, scale),
+        hole_to_hole=_mm_to_board(dsn, scale, hole_to_hole_mm) or 0,
+    )
+    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)
+    # pins on turned pads leave along their pad's axis: replay with the same exits
+    state._axis_exits = dict(routed._axis_exits)
+    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" if other.clearance else "rule area"
+        else:
+            what = ("trace/via of " if other.routed else "pad of ") + names.get(other.net_no, "?")
+        need = clearance if other is None or other.clearance else 0
+        short = (need - _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": [
+                                _wall_name(n, names) 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("--seed", type=int, help="route in this shuffled order, as bench.py does")
+    ap.add_argument("--negotiate", type=int, default=0, metavar="N", help="as the router's --negotiate")
+    ap.add_argument("--hole-to-hole", type=float, default=0.25, metavar="MM")
+    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, args.hole_to_hole, args.seed, args.negotiate)
+    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())

bench/drc_check.sh

@@ -0,0 +1,67 @@
+#!/usr/bin/env bash
+# Route one KiCad board with freeroute and judge the result with KiCad's DRC.
+#
+#   bench/drc_check.sh [--keep] <board.kicad_pcb> <out-dir> [freeroute args...]
+#
+# Copies the board (and its .kicad_pro) into <out-dir>, strips its tracks and
+# vias unless --keep is given (then they reach the router as fixed wiring),
+# exports the DSN through mckicad, routes, applies the session, and runs DRC
+# with zones refilled at every severity. Prints one line: time, copper added,
+# shorts, opens, hole problems (whatever severity the board gives them) and
+# the other errors. The source board is never touched.
+#
+# FREEROUTE (default: this checkout's .venv/bin/freeroute) and MCK (default
+# ~/claude/mckicad) pick the builds to judge.
+set -euo pipefail
+keep=0
+if [[ "${1:-}" == "--keep" ]]; then keep=1; shift; fi
+src="$1"; out="$2"; shift 2
+here="$(cd "$(dirname "$0")/.." && pwd)"
+FREEROUTE="${FREEROUTE:-$here/.venv/bin/freeroute}"
+MCK="${MCK:-$HOME/claude/mckicad}"
+rm -rf "$out"; mkdir -p "$out"
+cp "${src%.kicad_pcb}.kicad_pro" "$out/board.kicad_pro" 2>/dev/null || true
+
+if [[ $keep == 1 ]]; then
+    cp "$src" "$out/board.kicad_pcb"
+else
+    (cd "$MCK" && uv run --no-sync python - "$src" "$out/board.kicad_pcb" <<'EOF'
+import sys
+from mckicad.utils.sexp_tree import parse
+text = open(sys.argv[1]).read()
+spans = sorted((c.span for c in parse(text).children if c.tag in ("segment", "arc", "via")), reverse=True)
+for a, b in spans:
+    text = text[:a] + text[b:]
+open(sys.argv[2], "w").write(text)
+EOF
+    )
+fi
+
+(cd "$MCK" && uv run --no-sync python -c "
+from mckicad.utils.freerouting import FreeRoutingEngine
+assert FreeRoutingEngine().export_dsn_from_kicad('$out/board.kicad_pcb', '$out/board.dsn', {})") \
+    >/dev/null 2>&1 || { echo "$out: DSN export failed"; exit 1; }
+
+start=$(date +%s.%N)
+"$FREEROUTE" "$out/board.dsn" -do "$out/board.ses" "$@" >"$out/route.log" 2>&1 || true
+secs=$(python3 -c "print(round($(date +%s.%N)-$start,1))")
+[[ -s "$out/board.ses" ]] || { echo "$out: no session ($(tail -1 "$out/route.log"))"; exit 1; }
+
+(cd "$MCK" && uv run --no-sync python -c "
+from mckicad.utils.ses_apply import apply_ses_to_board as a
+r = a('$out/board.kicad_pcb', '$out/board.ses', '$out/board.kicad_pcb')
+print(r['segments_added'], r['vias_added'])" 2>/dev/null) >"$out/apply.txt"
+
+kicad-cli pcb drc --refill-zones --format json --severity-all \
+    -o "$out/drc.json" "$out/board.kicad_pcb" >/dev/null 2>&1 || true
+python3 - "$out" "$secs" <<'EOF'
+import collections, json, sys
+out, secs = sys.argv[1:]
+seg, via = open(f"{out}/apply.txt").read().split()
+d = json.load(open(f"{out}/drc.json"))
+errors = collections.Counter(v["type"] for v in d["violations"] if v.get("severity") == "error")
+other = collections.Counter(v["type"] for v in d["violations"] if v.get("severity") != "error")
+holes = {k: errors.pop(k, 0) + other.get(k, 0) for k in ("holes_co_located", "hole_to_hole")}
+print(f"{out}: {secs}s  {seg} seg {via} via  shorts {errors.pop('shorting_items', 0)}  "
+      f"opens {len(d.get('unconnected_items', []))}  holes {holes}  errors {dict(errors)}")
+EOF

src/freeroute/board/board.py

@@ -12,7 +12,7 @@ from __future__ import annotations
 from freeroute.geometry import IntBox
 
 from .clearance import ClearanceMatrix
-from .items import Item, ObstacleArea, Pin, Trace, Via
+from .items import ConductionArea, Item, ObstacleArea, Pin, Trace, Via
 from .layer import LayerStructure
 from .net import Nets
 
@@ -22,7 +22,7 @@ __all__ = ["BasicBoard"]
 class BasicBoard:
     """A board: layers, nets, clearances, a bounding box, and items."""
 
-    __slots__ = ("layer_structure", "nets", "clearance_matrix", "bounding_box", "_items")
+    __slots__ = ("layer_structure", "nets", "clearance_matrix", "bounding_box", "outline", "_items")
 
     def __init__(
         self,
@@ -35,6 +35,8 @@ class BasicBoard:
         self.nets = nets
         self.clearance_matrix = clearance_matrix
         self.bounding_box = bounding_box
+        #: the real board outline, when the DSN has a polygon boundary
+        self.outline = None
         self._items: list[Item] = []
 
     # --- layers -------------------------------------------------------------
@@ -55,11 +57,40 @@ class BasicBoard:
         return [it for it in self._items if isinstance(it, Pin)]
 
     def get_obstacle_areas(self) -> list[ObstacleArea]:
-        return [it for it in self._items if isinstance(it, ObstacleArea)]
+        """Keepouts. Copper zones are not obstacles; see get_conduction_areas."""
+        return [
+            it
+            for it in self._items
+            if isinstance(it, ObstacleArea) and not isinstance(it, ConductionArea)
+        ]
+
+    def get_conduction_areas(self) -> list[ConductionArea]:
+        return [it for it in self._items if isinstance(it, ConductionArea)]
 
     def get_traces(self) -> list[Trace]:
         return [it for it in self._items if isinstance(it, Trace)]
 
+    def get_fixed_copper(self) -> list[tuple[int, frozenset[int], IntBox]]:
+        """Copper already routed on the board (the DSN's ``wiring``), as
+        ``(net, layers, box)``. A track is its segments, its corners and the
+        round caps at its ends (as squares); a via is its largest pad."""
+        from freeroute.geometry.polyline import Polyline, PolylineShape, corner_box
+
+        out: list[tuple[int, frozenset[int], IntBox]] = []
+        for item in self._items:
+            if not item.fixed or not item.net_nos:
+                continue
+            net = item.net_nos[0]
+            if isinstance(item, Trace) and not item.is_empty():
+                layers = frozenset({item.layer})
+                for box in PolylineShape(Polyline(item.corners), item.half_width).tiles():
+                    out.append((net, layers, box))
+                for end in (item.corners[0], item.corners[-1]):
+                    out.append((net, layers, corner_box(end, item.half_width)))
+            elif isinstance(item, Via) and item.shape is not None:
+                out.append((net, frozenset(item.layers), item.shape.bounding_box()))
+        return out
+
     def get_vias(self) -> list[Via]:
         return [it for it in self._items if isinstance(it, Via)]
 

src/freeroute/board/build.py

@@ -12,9 +12,10 @@ model. It mirrors what FreeRouting's ``Structure.create_board`` / ``Library`` /
 * padstacks x placement -> :class:`Pin` items
 * keepouts -> :class:`ObstacleArea` items
 
-Pad geometry: a rectangle pad becomes an exact :class:`IntBox`; a circle pad its
-bounding box (documented approximation pending an exact circle tile); a convex
-polygon pad an exact :class:`Simplex`. Every pad is placed centred on its pin
+Pad geometry: a rectangle pad becomes an exact :class:`IntBox`; a circle pad a
+16-sided :class:`Simplex` drawn just outside it (its corners stand out by 2% of
+the radius, where the bounding box's stood out by 41%); a convex polygon pad an
+exact :class:`Simplex`. Every pad is placed centred on its pin
 location, so it contains that location by construction. Component rotation is
 applied to the pin position; the pad tile itself is not rotated (irrelevant to
 the containment invariant, and pads are centre-symmetric in practice).
@@ -23,20 +24,25 @@ the containment invariant, and pads are centre-symmetric in practice).
 from __future__ import annotations
 
 import math
+import re
 
 from freeroute.dsn.model import DsnBoard
 from freeroute.dsn.shapes import Circle, Path, Polygon, Rectangle, Shape
 from freeroute.geometry import FloatPoint, IntBox, IntPoint, IntVector, Simplex
+from freeroute.geometry.polygon_shape import PolygonShape
 
 from .board import BasicBoard
 from .clearance import ClearanceMatrix
-from .items import ObstacleArea, Pin
+from .items import ConductionArea, ObstacleArea, Pin, Trace, Via
 from .layer import Layer, LayerStructure
 from .net import Nets
 from .transform import CoordinateTransform
 
 __all__ = ["build_board"]
 
+# DSN units per micrometre, for drills KiCad gives in um in via padstack names
+_DSN_PER_UM = {"um": 1.0, "mm": 0.001, "mil": 1 / 25.4, "inch": 1 / 25400}
+
 
 def build_board(dsn: DsnBoard) -> BasicBoard:
     """Construct a :class:`BasicBoard` from a parsed :class:`DsnBoard`."""
@@ -49,9 +55,13 @@ def build_board(dsn: DsnBoard) -> BasicBoard:
     bounding_box = _build_bounding_box(dsn, transform)
 
     board = BasicBoard(layer_structure, nets, clearance, bounding_box)
+    board.outline = _build_outline(dsn, transform)
 
     _insert_pins(dsn, board, transform, terminal_to_net)
     _insert_keepouts(dsn, board, transform)
+    _insert_image_keepouts(dsn, board, transform)
+    _insert_zones(dsn, board, transform, nets)
+    _insert_wiring(dsn, board, transform, nets)
     return board
 
 
@@ -97,6 +107,18 @@ def _build_bounding_box(dsn: DsnBoard, transform: CoordinateTransform) -> IntBox
     return IntBox(llx, lly, urx, ury)
 
 
+def _build_outline(dsn: DsnBoard, transform: CoordinateTransform):
+    """The DSN boundary as a polygon, or None when it is not a polygon."""
+    from .outline import BoardOutline
+
+    shape = dsn.boundary
+    if not isinstance(shape, (Polygon, Path)):
+        return None
+    c = shape.coords
+    pts = [transform.dsn_to_board_point(c[i], c[i + 1]) for i in range(0, len(c) - 1, 2)]
+    return BoardOutline(pts) if len(pts) >= 3 else None
+
+
 def _shape_coords(shape: Shape) -> list[float]:
     if isinstance(shape, Rectangle):
         return list(shape.coords)
@@ -132,7 +154,7 @@ def _insert_pins(
                 location = _pin_location(place, dsn_pin, transform)
                 padstack = dsn.padstack(dsn_pin.padstack_name)
                 shape, layers = _pad_shape_and_layers(
-                    padstack, location, transform, layer_no, signal_layers
+                    padstack, place, dsn_pin, location, transform, layer_no, signal_layers
                 )
                 net_no = terminal_to_net.get((place.name, dsn_pin.name))
                 pin = Pin(
@@ -140,6 +162,7 @@ def _insert_pins(
                     component_no=id(place) & 0xFFFFFF,
                     fixed=True,
                     name=dsn_pin.name,
+                    component_ref=place.name,
                     padstack_name=dsn_pin.padstack_name,
                     location=location,
                     layers=layers,
@@ -148,22 +171,44 @@ def _insert_pins(
                 board.insert(pin)
 
 
+def _to_board_offset(place, x: float, y: float, pin_rotation: float = 0.0) -> FloatPoint:
+    """Image-relative DSN offset -> board-oriented DSN offset for a placed part.
+
+    The chain is: the pin's own rotation (pad shapes only), then the mirror of
+    a back-side part (x -> -x), then the part's rotation. Pin positions use the
+    same chain without the pin rotation, so pads and positions always agree.
+    """
+    p = FloatPoint(x, y)
+    if pin_rotation:
+        p = p.rotate(math.radians(pin_rotation), FloatPoint(0.0, 0.0))
+    if not place.is_front:
+        p = FloatPoint(-p.x, p.y)
+    if place.rotation:
+        p = p.rotate(math.radians(place.rotation), FloatPoint(0.0, 0.0))
+    return p
+
+
 def _pin_location(place, dsn_pin, transform: CoordinateTransform) -> IntPoint:
-    """Absolute board location of a pin: component origin + rotated pin offset."""
-    rel_x = -dsn_pin.x if not place.is_front else dsn_pin.x  # back side mirrors in x
-    rel = FloatPoint(rel_x, dsn_pin.y)
-    rotated = rel.rotate(math.radians(place.rotation), FloatPoint(0.0, 0.0))
-    return transform.dsn_to_board_point(place.x + rotated.x, place.y + rotated.y)
+    """Absolute board location of a pin: component origin + placed pin offset."""
+    rel = _to_board_offset(place, dsn_pin.x, dsn_pin.y)
+    return transform.dsn_to_board_point(place.x + rel.x, place.y + rel.y)
 
 
 def _pad_shape_and_layers(
     padstack,
+    place,
+    dsn_pin,
     location: IntPoint,
     transform: CoordinateTransform,
     layer_no: dict[str, int],
     signal_layers: list[int],
 ) -> tuple[object, list[int]]:
-    """A pad tile centred on ``location`` plus the layer indices it occupies."""
+    """A pad tile around ``location`` plus the layer indices it occupies.
+
+    A back-side part's pads move to the mirrored copper layer (F.Cu -> B.Cu on
+    a two-layer board), and the pad outline is placed through the same
+    rotation and mirror as the pin itself.
+    """
     if padstack is None or not padstack.shapes:
         # degenerate: a zero-size box at the location (still contains it)
         return IntBox(location.x, location.y, location.x, location.y), list(signal_layers)
@@ -176,12 +221,113 @@ def _pad_shape_and_layers(
             layers.add(layer_no[shape.layer])
     if not layers:
         layers = set(signal_layers)
+    if not place.is_front and signal_layers:
+        top, bottom = min(signal_layers), max(signal_layers)
+        layers = {top + bottom - layer if layer in signal_layers else layer for layer in layers}
 
-    tile = _pad_tile(padstack.shapes[0], transform)
+    # The largest of the padstack's shapes: per-layer shapes of a through-hole
+    # pad usually match, and when they do not the bigger one is the safe side.
+    shape = max(padstack.shapes, key=_shape_extent)
+    tile = _placed_pad_tile(shape, place, dsn_pin, transform)
     tile = tile.translate_by(IntVector(location.x, location.y))
     return tile, sorted(layers)
 
 
+def _shape_extent(shape: Shape) -> float:
+    coords = _shape_coords(shape)
+    if isinstance(shape, Circle):
+        return shape.diameter ** 2
+    if len(coords) < 4:
+        return 0.0
+    xs, ys = coords[0::2], coords[1::2]
+    return (max(xs) - min(xs)) * (max(ys) - min(ys))
+
+
+def _placed_pad_tile(shape: Shape, place, dsn_pin, transform: CoordinateTransform):
+    """The pad outline, rotated and mirrored with its part, relative to the pin."""
+    if isinstance(shape, Circle):
+        centre = _to_board_offset(place, shape.center_x, shape.center_y, dsn_pin.rotation)
+        r = round(transform.dsn_to_board(shape.diameter / 2))
+        cx = round(transform.dsn_to_board(centre.x))
+        cy = round(transform.dsn_to_board(centre.y))
+        return _circle_tile(cx, cy, r)
+    if isinstance(shape, Rectangle):
+        x0, y0, x1, y1 = shape.coords[:4]
+        corners = [(x0, y0), (x1, y0), (x1, y1), (x0, y1)]
+    elif isinstance(shape, (Polygon, Path)):
+        c = shape.coords
+        corners = [(c[i], c[i + 1]) for i in range(0, len(c) - 1, 2)]
+    else:
+        return _pad_tile(shape, transform)
+    # An oval pad is a path with a width (the aperture). Pad the centreline
+    # out by half the width in every direction; the square ends cover more
+    # than the round ones do, which is the safe side.
+    half = getattr(shape, "width", 0.0) / 2 if isinstance(shape, Path) else 0.0
+    if half:
+        corners = [(x + dx, y + dy) for x, y in corners for dx in (-half, half) for dy in (-half, half)]
+    pts = []
+    for x, y in corners:
+        p = _to_board_offset(place, x, y, dsn_pin.rotation)
+        pts.append(IntPoint(round(transform.dsn_to_board(p.x)), round(transform.dsn_to_board(p.y))))
+    # An oval's padded corners are not in outline order, and a mirrored
+    # part reverses the winding: take the convex hull, then either winding.
+    hull = _convex_hull(pts)
+    if len(hull) >= 3:
+        for corners in (hull, hull[::-1]):
+            simplex = Simplex.from_corners(corners)
+            if not simplex.is_empty():
+                return simplex
+    xs = [p.x for p in pts] or [0]
+    ys = [p.y for p in pts] or [0]
+    return IntBox(min(xs), min(ys), max(xs), max(ys))
+
+
+_CIRCLE_SIDES = 16
+
+
+def _circle_tile(cx: int, cy: int, r: int):
+    """A polygon around the circle, every side touching it. A square around a
+    big round pad (a mounting hole) puts phantom copper in its corners that
+    blocks legal routes past it; this stays outside the circle, so the router
+    is still never closer than KiCad measures."""
+    if r < 8:
+        return IntBox(cx - r, cy - r, cx + r, cy + r)
+    reach = r / math.cos(math.pi / _CIRCLE_SIDES)
+    corners = []
+    for k in range(_CIRCLE_SIDES):
+        a = (k + 0.5) * 2 * math.pi / _CIRCLE_SIDES
+        dx, dy = reach * math.cos(a), reach * math.sin(a)
+        # round away from the centre so the polygon never cuts into the circle
+        corners.append(IntPoint(cx + math.copysign(math.ceil(abs(dx)), dx),
+                                cy + math.copysign(math.ceil(abs(dy)), dy)))
+    corners = [IntPoint(int(p.x), int(p.y)) for p in corners]
+    for winding in (corners, corners[::-1]):
+        simplex = Simplex.from_corners(winding)
+        if not simplex.is_empty():
+            return simplex
+    return IntBox(cx - r, cy - r, cx + r, cy + r)
+
+
+def _convex_hull(pts: list[IntPoint]) -> list[IntPoint]:
+    """The convex hull of ``pts`` counter-clockwise, collinear points dropped."""
+    ps = sorted({(p.x, p.y) for p in pts})
+    if len(ps) < 3:
+        return [IntPoint(x, y) for x, y in ps]
+
+    def cross(o, a, b):
+        return (a[0] - o[0]) * (b[1] - o[1]) - (a[1] - o[1]) * (b[0] - o[0])
+
+    def half(points):
+        out: list[tuple[int, int]] = []
+        for p in points:
+            while len(out) >= 2 and cross(out[-2], out[-1], p) <= 0:
+                out.pop()
+            out.append(p)
+        return out[:-1]
+
+    return [IntPoint(x, y) for x, y in half(ps) + half(ps[::-1])]
+
+
 def _pad_tile(shape: Shape, transform: CoordinateTransform):
     """A board-relative pad tile from a DSN padstack shape (centred near origin)."""
     if isinstance(shape, Rectangle):
@@ -191,7 +337,7 @@ def _pad_tile(shape: Shape, transform: CoordinateTransform):
         r = round(transform.dsn_to_board(shape.diameter / 2))
         cx = round(transform.dsn_to_board(shape.center_x))
         cy = round(transform.dsn_to_board(shape.center_y))
-        return IntBox(cx - r, cy - r, cx + r, cy + r)  # bounding-box approximation
+        return _circle_tile(cx, cy, r)
     if isinstance(shape, (Polygon, Path)):
         coords = shape.coords
         pts = [
@@ -219,11 +365,14 @@ def _insert_keepouts(dsn: DsnBoard, board: BasicBoard, transform: CoordinateTran
     signal_layers = [i for i, layer in enumerate(dsn.layers) if layer.is_signal]
 
     for keepout in dsn.keepouts:
+        # A place_keepout only restricts where parts go, not copper.
+        if keepout.kind == "place_keepout":
+            continue
         area = keepout.area
         if area is None or area.border is None:
             continue
-        tile = _area_border_tile(area.border, transform)
-        if tile is None:
+        tiles = _area_border_tiles(area.border, transform)
+        if not tiles:
             continue
         border_layer = area.border.layer
         if border_layer in ("signal", "pcb"):
@@ -237,11 +386,48 @@ def _insert_keepouts(dsn: DsnBoard, board: BasicBoard, transform: CoordinateTran
                 ObstacleArea(
                     name=keepout.area.name,
                     layer=layer_index,
-                    tiles=[tile],
+                    tiles=tiles,
+                    blocks_wires=keepout.kind != "via_keepout",
+                    blocks_vias=keepout.kind != "wire_keepout",
+                    clearance=not is_rule_area(keepout.area.name),
                 )
             )
 
 
+#: a structure keepout named with this prefix is a KiCad rule area (mckicad
+#: names them on export); it is checked for overlap only
+RULE_AREA_PREFIX = "rule_area"
+
+
+def is_rule_area(name: str | None) -> bool:
+    return bool(name) and name.startswith(RULE_AREA_PREFIX)
+
+
+def _area_border_tiles(shape: Shape, transform: CoordinateTransform) -> list:
+    """Convex board tiles covering a keepout border shape.
+
+    Polygons are split into convex pieces rather than wrapped in one convex
+    tile: KiCad exports a rule area with a hole (a no-track ring along the
+    board edge, say) as a single keyhole polygon, and its convex hull is the
+    whole board.
+    """
+    if isinstance(shape, (Polygon, Path)):
+        coords = shape.coords
+        pts = [
+            IntPoint(
+                round(transform.dsn_to_board(coords[i])),
+                round(transform.dsn_to_board(coords[i + 1])),
+            )
+            for i in range(0, len(coords) - 1, 2)
+        ]
+        if len(pts) >= 3:
+            pieces = [t for t in PolygonShape(pts).split_to_convex() if not t.is_empty()]
+            if pieces:
+                return pieces
+    tile = _area_border_tile(shape, transform)
+    return [tile] if tile is not None else []
+
+
 def _area_border_tile(shape: Shape, transform: CoordinateTransform):
     """Convert an absolute-coordinate keepout border shape to one board tile."""
     if isinstance(shape, Rectangle):
@@ -269,3 +455,145 @@ def _area_border_tile(shape: Shape, transform: CoordinateTransform):
         ys = [p.y for p in pts] or [0]
         return IntBox(min(xs), min(ys), max(xs), max(ys))
     return None
+
+
+def _insert_image_keepouts(dsn: DsnBoard, board: BasicBoard, transform: CoordinateTransform) -> None:
+    """Keepouts declared inside a footprint, placed with each instance.
+
+    KiCad exports copper that has no pin number this way, for instance the
+    plated ring of a mounting hole, so skipping them leaves copper the router
+    cannot see.
+    """
+    images = {img.name: img for img in dsn.images}
+    layer_no = {layer.name: i for i, layer in enumerate(dsn.layers)}
+    signal_layers = [i for i, layer in enumerate(dsn.layers) if layer.is_signal]
+    for placement in dsn.placements:
+        image = images.get(placement.lib_name)
+        if image is None:
+            continue
+        areas = [
+            *((a, True, True) for a in image.keepouts),
+            *((a, False, True) for a in image.via_keepouts),
+            *((a, True, False) for a in image.wire_keepouts),
+        ]
+        if not areas:
+            continue
+        for place in placement.places:
+            if place.x is None or place.y is None:
+                continue
+            for area, blocks_wires, blocks_vias in areas:
+                border = area.border
+                if border is None:
+                    continue
+                tiles = _placed_area_tiles(border, place, transform)
+                if not tiles:
+                    continue
+                if border.layer in ("signal", "pcb") or border.layer not in layer_no:
+                    layers = list(signal_layers)
+                else:
+                    layers = [layer_no[border.layer]]
+                if not place.is_front and signal_layers:
+                    top, bottom = min(signal_layers), max(signal_layers)
+                    layers = [top + bottom - layer for layer in layers]
+                for layer_index in layers:
+                    board.insert(
+                        ObstacleArea(
+                            name=area.name, layer=layer_index, tiles=tiles,
+                            blocks_wires=blocks_wires, blocks_vias=blocks_vias,
+                        )
+                    )
+
+
+def _placed_area_tiles(shape: Shape, place, transform: CoordinateTransform) -> list:
+    """An image-relative area border placed with its part, as convex board tiles."""
+    def to_board(x: float, y: float) -> IntPoint:
+        p = _to_board_offset(place, x, y)
+        return transform.dsn_to_board_point(place.x + p.x, place.y + p.y)
+
+    if isinstance(shape, Circle):
+        c = to_board(shape.center_x, shape.center_y)
+        r = round(transform.dsn_to_board(shape.diameter / 2))
+        return [IntBox(c.x - r, c.y - r, c.x + r, c.y + r)]
+    if isinstance(shape, Rectangle):
+        x0, y0, x1, y1 = shape.coords[:4]
+        pts = [to_board(x, y) for x, y in ((x0, y0), (x1, y0), (x1, y1), (x0, y1))]
+    elif isinstance(shape, (Polygon, Path)):
+        c = shape.coords
+        pts = [to_board(c[i], c[i + 1]) for i in range(0, len(c) - 1, 2)]
+    else:
+        return []
+    if len(pts) < 3:
+        return []
+    return [tile for tile in PolygonShape(pts).split_to_convex() if not tile.is_empty()]
+
+
+def _insert_wiring(dsn: DsnBoard, board: BasicBoard, transform: CoordinateTransform, nets) -> None:
+    """Tracks and vias already on the board, as fixed copper of their nets."""
+    layer_no = {layer.name: i for i, layer in enumerate(dsn.layers)}
+    signal_layers = [i for i, layer in enumerate(dsn.layers) if layer.is_signal]
+    numbers = {net.name: net.net_number for net in nets}
+    for wire in dsn.wires:
+        if wire.net not in numbers or wire.layer not in layer_no:
+            continue
+        c = wire.coords
+        corners = [transform.dsn_to_board_point(c[i], c[i + 1]) for i in range(0, len(c) - 1, 2)]
+        if len(corners) < 2:
+            continue
+        board.insert(
+            Trace(
+                net_nos=[numbers[wire.net]], fixed=True, layer=layer_no[wire.layer],
+                half_width=max(round(transform.dsn_to_board(wire.width / 2)), 1), corners=corners,
+            )
+        )
+    for via in dsn.vias:
+        padstack = dsn.padstack(via.padstack)
+        if via.net not in numbers or padstack is None or not padstack.shapes:
+            continue
+        layers: set[int] = set()
+        for shape in padstack.shapes:
+            if shape.layer in ("signal", "pcb"):
+                layers.update(signal_layers)
+            elif shape.layer in layer_no:
+                layers.add(layer_no[shape.layer])
+        location = transform.dsn_to_board_point(via.x, via.y)
+        pad = _pad_tile(max(padstack.shapes, key=_shape_extent), transform)
+        box = pad.bounding_box()
+        drill = re.search(r"_([\d.]+):([\d.]+)_um", via.padstack)
+        drill_board = (
+            round(transform.dsn_to_board(float(drill.group(2)) * _DSN_PER_UM.get(dsn.unit, 1.0)))
+            if drill else 0
+        )
+        board.insert(
+            Via(
+                net_nos=[numbers[via.net]], fixed=True, padstack_name=via.padstack,
+                drill=drill_board, location=location, layers=sorted(layers or signal_layers),
+                shape=IntBox(box.ll.x + location.x, box.ll.y + location.y,
+                             box.ur.x + location.x, box.ur.y + location.y),
+            )
+        )
+
+
+def _insert_zones(dsn: DsnBoard, board: BasicBoard, transform: CoordinateTransform, nets) -> None:
+    """Each DSN plane as a ConductionArea of its net on its layer."""
+    layer_no = {layer.name: i for i, layer in enumerate(dsn.layers)}
+    numbers = {net.name: net.net_number for net in nets}
+    for plane in dsn.planes:
+        shape = plane.shape
+        if plane.net not in numbers or shape.layer not in layer_no:
+            continue
+        if not isinstance(shape, (Polygon, Path)):
+            continue
+        c = shape.coords
+        pts = [transform.dsn_to_board_point(c[i], c[i + 1]) for i in range(0, len(c) - 1, 2)]
+        if len(pts) < 3:
+            continue
+        polygon = PolygonShape(pts)
+        tiles = [t for t in polygon.split_to_convex() if not t.is_empty()]
+        if not tiles:
+            continue
+        board.insert(
+            ConductionArea(
+                net_nos=[numbers[plane.net]], name=plane.net, layer=layer_no[shape.layer],
+                tiles=tiles, polygon=polygon, blocks_wires=False, blocks_vias=False,
+            )
+        )

src/freeroute/board/items.py

@@ -48,6 +48,8 @@ class Pin(Item):
     """A component pin: a pad shape on one or more layers at a fixed location."""
 
     name: str = ""
+    #: reference designator of the owning component, for diagnostics
+    component_ref: str = ""
     padstack_name: str = ""
     location: IntPoint = field(default_factory=lambda: IntPoint(0, 0))
     #: layer indices the pad occupies (all signal layers when spanning)
@@ -70,6 +72,15 @@ class ObstacleArea(Item):
     name: str | None = None
     layer: int = 0
     tiles: list = field(default_factory=list)
+    #: a DSN keepout blocks both; wire_keepout only traces (KiCad's "no
+    #: tracks" rule area, where vias are allowed), via_keepout only vias
+    blocks_wires: bool = True
+    blocks_vias: bool = True
+    #: False for a KiCad rule area: copper may not overlap it but may touch
+    #: it, since KiCad's DRC applies no clearance to a rule area. Every other
+    #: keepout may stand for copper (a net tie, a track kept as it is), so it
+    #: keeps the clearance unless named as a rule area.
+    clearance: bool = True
 
     def is_obstacle(self) -> bool:
         return True
@@ -85,7 +96,16 @@ class ObstacleArea(Item):
 
 @dataclass
 class ConductionArea(ObstacleArea):
-    """A power-plane conduction area (an obstacle carrying a net)."""
+    """A copper zone of one net (a DSN plane): not an obstacle to routing,
+    since KiCad refills it around other nets' copper, but copper of its net:
+    pads it touches are connected through it, and a route of its net ends on
+    it by placing a via inside it."""
+
+    #: the zone outline, for point containment
+    polygon: object = None
+
+    def is_obstacle(self) -> bool:
+        return False
 
 
 @dataclass
@@ -94,6 +114,11 @@ class Via(Item):
 
     padstack_name: str = ""
     location: IntPoint = field(default_factory=lambda: IntPoint(0, 0))
+    #: layer indices the via's pads occupy, and the largest pad as a box
+    layers: list[int] = field(default_factory=list)
+    shape: object = None
+    #: drill diameter in board units, when the padstack name gives it
+    drill: int = 0
 
 
 @dataclass

src/freeroute/board/outline.py

@@ -0,0 +1,122 @@
+"""The board outline as a polygon, and clearance tests against its edge.
+
+The DSN boundary is the real Edge.Cuts outline, rounded corners and all
+(arcs come as short segments). Routing inside its bounding box instead lets
+copper cut across a rounded corner closer to the edge than the board allows.
+"""
+
+from __future__ import annotations
+
+import math
+
+from freeroute.geometry import IntBox, IntPoint
+
+
+class BoardOutline:
+    """A simple polygon in board units, with point and box clearance tests."""
+
+    def __init__(self, points: list[IntPoint]) -> None:
+        pts = list(points)
+        if len(pts) > 1 and pts[0] == pts[-1]:
+            pts.pop()
+        self.points = pts
+        self._edges = [(pts[i], pts[(i + 1) % len(pts)]) for i in range(len(pts))]
+
+    def contains(self, p: IntPoint) -> bool:
+        """Even-odd point in polygon; points on the edge count as outside."""
+        inside = False
+        x, y = p.x, p.y
+        for a, b in self._edges:
+            if (a.y > y) != (b.y > y):
+                t = (y - a.y) / (b.y - a.y)
+                if x < a.x + t * (b.x - a.x):
+                    inside = not inside
+        return inside
+
+    def row_inside_spans(self, y: float) -> list[tuple[float, float]]:
+        """The x intervals inside the polygon along the horizontal line at ``y``."""
+        xs = sorted(
+            a.x + (y - a.y) * (b.x - a.x) / (b.y - a.y)
+            for a, b in self._edges
+            if (a.y > y) != (b.y > y)
+        )
+        # an odd count (a line grazing a vertex) drops the unpaired crossing
+        return list(zip(xs[0::2], xs[1::2], strict=False))
+
+    def edges(self):
+        return self._edges
+
+    def edge_distance(self, p: IntPoint) -> float:
+        return min(_point_segment(p, a, b) for a, b in self._edges)
+
+    def point_clear(self, p: IntPoint, reach: float) -> bool:
+        """Copper reaching ``reach`` around ``p`` stays inside, clear of the edge."""
+        return self.contains(p) and self.edge_distance(p) >= reach
+
+    def box_clear(self, box: IntBox, clearance: float) -> bool:
+        """``box`` lies inside the outline at least ``clearance`` from its edge."""
+        corners = [
+            IntPoint(box.ll.x, box.ll.y),
+            IntPoint(box.ur.x, box.ll.y),
+            IntPoint(box.ur.x, box.ur.y),
+            IntPoint(box.ll.x, box.ur.y),
+        ]
+        if not all(self.contains(c) for c in corners):
+            return False
+        return all(_segment_box(a, b, box) >= clearance for a, b in self._edges)
+
+
+def _point_segment(p: IntPoint, a: IntPoint, b: IntPoint) -> float:
+    dx, dy = b.x - a.x, b.y - a.y
+    length2 = dx * dx + dy * dy
+    if length2 == 0:
+        return math.hypot(p.x - a.x, p.y - a.y)
+    t = max(0.0, min(1.0, ((p.x - a.x) * dx + (p.y - a.y) * dy) / length2))
+    return math.hypot(p.x - (a.x + t * dx), p.y - (a.y + t * dy))
+
+
+def _point_box(p: IntPoint, box: IntBox) -> float:
+    dx = max(box.ll.x - p.x, 0, p.x - box.ur.x)
+    dy = max(box.ll.y - p.y, 0, p.y - box.ur.y)
+    return math.hypot(dx, dy)
+
+
+def _segment_box(a: IntPoint, b: IntPoint, box: IntBox) -> float:
+    """Distance between segment ``ab`` and an axis-aligned box (0 if they touch)."""
+    if _segments_cross_box(a, b, box):
+        return 0.0
+    corners = [
+        IntPoint(box.ll.x, box.ll.y),
+        IntPoint(box.ur.x, box.ll.y),
+        IntPoint(box.ur.x, box.ur.y),
+        IntPoint(box.ll.x, box.ur.y),
+    ]
+    return min(
+        _point_box(a, box),
+        _point_box(b, box),
+        *(_point_segment(c, a, b) for c in corners),
+    )
+
+
+def _segments_cross_box(a: IntPoint, b: IntPoint, box: IntBox) -> bool:
+    """Liang-Barsky clip: does segment ``ab`` enter the box?"""
+    t0, t1 = 0.0, 1.0
+    dx, dy = b.x - a.x, b.y - a.y
+    for p, q in (
+        (-dx, a.x - box.ll.x),
+        (dx, box.ur.x - a.x),
+        (-dy, a.y - box.ll.y),
+        (dy, box.ur.y - a.y),
+    ):
+        if p == 0:
+            if q < 0:
+                return False
+        else:
+            r = q / p
+            if p < 0:
+                t0 = max(t0, r)
+            else:
+                t1 = min(t1, r)
+            if t0 > t1:
+                return False
+    return True

src/freeroute/board/search_tree.py

@@ -18,7 +18,7 @@ from __future__ import annotations
 
 from dataclasses import dataclass
 
-from freeroute.geometry import IntBox, Simplex, overlaps_2d, segment_octagon
+from freeroute.geometry import IntBox, IntPoint, Simplex, overlaps_2d, segment_octagon, segment_slab
 
 __all__ = ["TreeShape", "ShapeSearchTree"]
 
@@ -47,6 +47,11 @@ class TreeShape:
     routed: bool = False
     exact: Simplex | None = None
     seg: tuple | None = None  # (a: IntPoint, b: IntPoint, half_width: int)
+    #: which copper a keepout tile stops: "all", "wires" (a wire_keepout,
+    #: vias allowed) or "vias" (a via_keepout)
+    blocks: str = "all"
+    #: False for a rule area: copper may touch it, only overlap counts
+    clearance: bool = True
 
     def on_layer(self, layer: int) -> bool:
         return layer in self.layers
@@ -58,7 +63,9 @@ class TreeShape:
         segment swept by ``half_width + clearance`` (exact integer superset)."""
         if self.seg is None:
             return self.tile.offset(clearance)
-        a, b, half_width = self.seg
+        a, b, half_width = self.seg[-3:]
+        if self.seg[0] == "slab":  # a slanted pin exit, at any angle
+            return segment_slab(a, b, half_width + clearance)
         return segment_octagon(a, b, half_width + clearance)
 
 
@@ -118,17 +125,27 @@ class ShapeSearchTree:
                     result.append(shape)
         return result
 
-    def clearance_conflict(self, box: IntBox, net_no: int, layer: int, clearance: int) -> bool:
+    def clearance_conflict(
+        self, box: IntBox, net_no: int, layer: int, clearance: int, kind: str = "wire"
+    ) -> bool:
         """True if placing ``box`` (of ``net_no`` on ``layer``) would come *closer
         than* ``clearance`` to a different net's tile on that layer (exact).
 
         Uses a strict 2-D overlap of the ``clearance``-expanded box, so tiles
         exactly ``clearance`` apart (touching after expansion) are allowed.
+        A rule area (``clearance=False``) only has to be clear of the copper
+        itself.
         """
         expanded = box.offset(clearance)
         for shape in self.overlapping(expanded):
             if shape.net_no == net_no or not shape.on_layer(layer):
                 continue
+            if shape.blocks != "all" and shape.blocks != kind + "s":
+                continue  # a wire-only keepout does not stop a via, and so on
+            if not shape.clearance:
+                if shape.tile.overlaps(box):
+                    return True
+                continue
             if shape.exact is not None:
                 if overlaps_2d(shape.exact, expanded):
                     return True
@@ -136,6 +153,36 @@ class ShapeSearchTree:
                 return True
         return False
 
+    def segment_conflict(
+        self, a: IntPoint, b: IntPoint, half_width: int, net_no: int, layer: int,
+        clearance: int, kind: str = "wire",
+    ) -> bool:
+        """:meth:`clearance_conflict` for a slanted segment, checked on its
+        exact swept copper instead of its bounding box (which would reach the
+        neighbouring pads of a pin leaving along its turned pad's axis)."""
+        copper = segment_slab(a, b, half_width)
+        grown = segment_slab(a, b, half_width + clearance)
+        for shape in self.overlapping(grown.bounding_box()):
+            if shape.net_no == net_no or not shape.on_layer(layer):
+                continue
+            if shape.blocks != "all" and shape.blocks != kind + "s":
+                continue
+            other = shape.exact if shape.exact is not None else shape.tile
+            if overlaps_2d(copper if not shape.clearance else grown, other):
+                return True
+        return False
+
+    def rule_area_overlap(self, box: IntBox, layer: int, kind: str = "wire") -> bool:
+        """True if ``box`` overlaps a rule area on ``layer`` that stops ``kind``."""
+        for shape in self.overlapping(box):
+            if shape.clearance or not shape.on_layer(layer):
+                continue
+            if shape.blocks != "all" and shape.blocks != kind + "s":
+                continue
+            if shape.tile.overlaps(box):
+                return True
+        return False
+
     def clearance_conflict_shape(
         self, region, net_no: int, layer: int
     ) -> bool:
@@ -162,6 +209,8 @@ class ShapeSearchTree:
         overlap). Static pad-vs-pad spacing in the source design is not counted.
         """
         for shape in self.all_shapes():
+            if not shape.routed:
+                continue  # a pair with routed copper is checked from that side
             expanded = shape.tile.offset(clearance)
             grown = None  # exact clearance region, built lazily only for diagonals
             for other in self.overlapping(expanded):
@@ -171,6 +220,13 @@ class ShapeSearchTree:
                     continue  # static input pair (e.g. pad vs pad) — not a routing DRC
                 if not (shape.layers & other.layers):
                     continue
+                if not (shape.clearance and other.clearance):
+                    # a rule area: only an overlap is a violation
+                    mine = shape.exact if shape.exact is not None else shape.tile
+                    theirs = other.exact if other.exact is not None else other.tile
+                    if overlaps_2d(mine, theirs):
+                        return shape
+                    continue
                 if shape.exact is None and other.exact is None:
                     if other.tile.overlaps(expanded):  # byte-identical box path
                         return shape

src/freeroute/cli.py

@@ -19,6 +19,7 @@ import argparse
 import sys
 
 from freeroute.dsn.reader import parse_dsn
+from freeroute.route.orders import best_of_orders, promote_failures
 from freeroute.route.pipeline import (
     build_exact_routing_result,
     build_rooms_routing_result,
@@ -29,8 +30,11 @@ 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"}),
-    "exact": frozenset({"shove", "diagonal", "rip_up", "max_passes"}),
+    "grid": frozenset({"rip_up", "max_passes", "seed", "orders", "promote", "access", "negotiate", "rollback", "tree"}),
+    "exact": frozenset({
+        "shove", "diagonal", "rip_up", "max_passes", "seed", "orders", "promote", "access",
+        "negotiate", "rollback", "tree", "window",
+    }),
     "room": frozenset({"shove", "pack"}),
 }
 
@@ -41,6 +45,14 @@ _FLAG_NAMES = {
     "diagonal": "--diagonal",
     "rip_up": "--no-rip-up",
     "max_passes": "-mp/--max-passes",
+    "seed": "--seed",
+    "orders": "--orders",
+    "promote": "--promote-failures",
+    "access": "--access-cost",
+    "negotiate": "--negotiate",
+    "rollback": "--no-rollback",
+    "tree": "--no-tree",
+    "window": "--window-reroute",
 }
 
 
@@ -110,6 +122,134 @@ def build_parser() -> argparse.ArgumentParser:
         help="disable rip-up-and-retry (grid and exact engines)",
     )
     parser.add_argument("--layers", help="comma-separated signal layer indices to route on")
+    parser.add_argument(
+        "--grid-resolution",
+        type=int,
+        default=None,
+        metavar="K",
+        help="grid and exact engines: cells K times finer than trace + clearance; "
+        "default 2 for exact (reaches 0.5 mm pitch pins), 1 for grid",
+    )
+    parser.add_argument(
+        "--heuristic-weight",
+        type=float,
+        default=1.0,
+        metavar="W",
+        help="exact engine: weighted A* (W >= 1); larger is faster, routes at most "
+        "W times the shortest length (default 1)",
+    )
+    parser.add_argument(
+        "--edge-clearance",
+        type=float,
+        metavar="MM",
+        help="copper to board-edge clearance in mm, e.g. KiCad's min_copper_edge_clearance "
+        "(the DSN does not carry it); default 0: copper only has to stay inside the outline",
+    )
+    parser.add_argument(
+        "--seed",
+        type=int,
+        metavar="N",
+        help="grid and exact engines: shuffle the order connections are routed in; "
+        "the same seed gives the same result (default: fewer-pin nets first)",
+    )
+    parser.add_argument(
+        "--orders",
+        type=int,
+        metavar="N",
+        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(
+        "--negotiate",
+        type=int,
+        metavar="N",
+        help="grid and exact engines: before routing, N rounds of negotiation on the empty "
+        "board, where routes may share space at a price that rises where they compete; "
+        "the contested cells then cost extra in the real routing (default 0: off)",
+    )
+    parser.add_argument(
+        "--no-rollback",
+        dest="rollback",
+        action="store_false",
+        help="grid and exact engines: keep every rip-up, as before. By default the "
+        "connections a rip-up displaces are rerouted at once and the rip-up is undone "
+        "if fewer connections end up routed",
+    )
+    parser.add_argument(
+        "--no-tree",
+        dest="tree_nets",
+        action="store_false",
+        help="grid and exact engines: join a multi-pin net's pins as a chain in pin "
+        "order, each connection ending on one chosen pin, as before. By default they are "
+        "paired by a minimum spanning tree and a connection may end on copper its net "
+        "has already routed",
+    )
+    parser.add_argument(
+        "--window-reroute",
+        type=int,
+        metavar="N",
+        help="exact engine: after routing, N rounds of window re-routes: around each "
+        "connection still unrouted, the nets routed wholly inside a window are ripped and "
+        "the window routed again on a finer grid, kept only if fewer connections are left "
+        "unrouted; each round doubles the window's margin (default 0: off)",
+    )
+    parser.add_argument(
+        "--window-resolution",
+        type=int,
+        default=4,
+        metavar="K",
+        help="the window re-route's grid resolution (default 4)",
+    )
+    parser.add_argument(
+        "--window-budget",
+        type=float,
+        default=0.25,
+        metavar="F",
+        help="the window re-route stops starting windows once it has spent this share "
+        "of the routing's own time (default 0.25)",
+    )
+    parser.add_argument(
+        "--window-cap",
+        type=int,
+        default=40,
+        metavar="W",
+        help="at most this many windows per round, smallest first (default 40)",
+    )
+    parser.add_argument(
+        "--window-margin",
+        type=float,
+        default=1.5,
+        metavar="MM",
+        help="the first round's window margin around the stuck connection's pins (default 1.5)",
+    )
+    parser.add_argument(
+        "--hole-to-hole",
+        type=float,
+        default=0.25,
+        metavar="MM",
+        help="grid and exact engines: least distance between the edges of any two via "
+        "holes, of one net or two (KiCad's min_hole_to_hole; default 0.25)",
+    )
+    parser.add_argument(
+        "--jobs",
+        type=int,
+        metavar="J",
+        help="processes for --orders (default: one per order, up to the CPU count)",
+    )
     return parser
 
 
@@ -129,6 +269,14 @@ def main(argv: list[str] | None = None) -> int:
             ("diagonal", args.diagonal),
             ("rip_up", args.no_rip_up),
             ("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),
+            ("negotiate", args.negotiate is not None),
+            ("rollback", not args.rollback),
+            ("tree", not args.tree_nets),
+            ("window", args.window_reroute is not None),
         )
         if asked
     ]
@@ -150,21 +298,93 @@ def main(argv: list[str] | None = None) -> int:
     rip_up = not args.no_rip_up
     max_passes = args.max_passes if args.max_passes is not None else 10
 
+    if args.orders is not None and args.orders < 1:
+        parser.error("--orders must be at least 1")
     if args.engine == "exact":
-        result = build_exact_routing_result(
-            dsn,
-            layers=layers,
-            shove=args.shove,
-            diagonal=args.diagonal,
-            rip_up=rip_up,
-            max_passes=max_passes,
+        options = {
+            "layers": layers,
+            "shove": args.shove,
+            "diagonal": args.diagonal,
+            "rip_up": rip_up,
+            "max_passes": max_passes,
+            "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,
+            "negotiate": args.negotiate or 0,
+            "hole_to_hole_mm": args.hole_to_hole,
+            "rollback": args.rollback,
+            "tree_nets": args.tree_nets,
+            "window_reroute": args.window_reroute or 0,
+            "window_resolution": args.window_resolution,
+            "window_margin_mm": args.window_margin,
+            "window_budget": args.window_budget,
+            "window_cap": args.window_cap,
+        }
+    elif args.engine == "grid":
+        options = {
+            "layers": layers,
+            "rip_up": rip_up,
+            "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,
+            "negotiate": args.negotiate or 0,
+            "hole_to_hole_mm": args.hole_to_hole,
+            "rollback": args.rollback,
+            "tree_nets": args.tree_nets,
+        }
+    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.engine == "room":
-        result = build_rooms_routing_result(dsn, layers=layers, shove=args.shove, pack=args.pack)
+    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
+        )
+        counts = ", ".join(f"{'default' if s is None else s}: {m}" for s, (m, _z) in tried)
+        print(
+            f"freeroute: tried {len(tried)} orders, kept "
+            f"{'the default order' if kept is None else f'--seed {kept}'} (unrouted {counts})",
+            file=sys.stderr,
+        )
+    elif args.engine == "exact":
+        result = build_exact_routing_result(dsn, seed=args.seed, **options)
     else:
-        result = build_routing_result(dsn, layers=layers, rip_up=rip_up, max_passes=max_passes)
+        result = build_routing_result(dsn, seed=args.seed, **options)
 
     ses_text = write_ses(dsn, result)
+    missing = [u for u in result.unrouted if not u[3]]
+    in_zone = [u for u in result.unrouted if u[3]]
+    if missing:
+        # the SES is still written; say plainly what it is missing
+        print(f"freeroute: {len(missing)} connection(s) not routed:", file=sys.stderr)
+        for net, a, b, _zone in missing:
+            print(f"  {net}: {a} to {b}", file=sys.stderr)
+    if result.narrowed:
+        print(
+            f"freeroute: {len(result.narrowed)} connection(s) of a wider net class only fitted "
+            "at the default width; their nets are written at the default width:",
+            file=sys.stderr,
+        )
+        for net, a, b in result.narrowed:
+            print(f"  {net}: {a} to {b}", file=sys.stderr)
+    if in_zone:
+        print(
+            f"freeroute: {len(in_zone)} more connection(s) left to a zone fill that may join them:",
+            file=sys.stderr,
+        )
+        for net, a, b, zone in in_zone:
+            print(f"  {net}: {a} to {b} (both in zone {zone})", file=sys.stderr)
 
     if args.output:
         with open(args.output, "w", encoding="utf-8") as f:

src/freeroute/dsn/model.py

@@ -27,6 +27,8 @@ __all__ = [
     "NetPin",
     "Net",
     "NetClass",
+    "WiringVia",
+    "WiringWire",
     "Keepout",
     "DsnBoard",
 ]
@@ -112,6 +114,7 @@ class Image:
     outlines: list[Shape] = field(default_factory=list)
     keepouts: list[Area] = field(default_factory=list)
     via_keepouts: list[Area] = field(default_factory=list)
+    wire_keepouts: list[Area] = field(default_factory=list)
     place_keepouts: list[Area] = field(default_factory=list)
 
 
@@ -169,12 +172,40 @@ class NetClass:
     via_rule: str | None = None
 
 
+@dataclass
+class Plane:
+    """A ``(plane <net> <shape>)``: a copper zone of that net (KiCad's zones)."""
+
+    net: str
+    shape: Shape
+
+
 @dataclass
 class Keepout:
     """A structure-level keepout area with its kind."""
 
     area: Area
-    kind: str = "keepout"  # keepout | via_keepout | place_keepout
+    kind: str = "keepout"  # keepout | via_keepout | wire_keepout | place_keepout
+
+
+@dataclass
+class WiringWire:
+    """A track already on the board: ``(wire (path LAYER WIDTH x y ...) (net N))``."""
+
+    net: str
+    layer: str
+    width: float
+    coords: list[float] = field(default_factory=list)
+
+
+@dataclass
+class WiringVia:
+    """A via already on the board: ``(via PADSTACK x y (net N))``."""
+
+    net: str
+    padstack: str
+    x: float
+    y: float
 
 
 @dataclass
@@ -186,6 +217,11 @@ class DsnBoard:
     resolution: Resolution = field(default_factory=Resolution)
     unit: str = "mil"
     layers: list[Layer] = field(default_factory=list)
+    #: copper zones, as planes of a net
+    planes: list[Plane] = field(default_factory=list)
+    #: copper already routed (the ``wiring`` scope), kept fixed
+    wires: list[WiringWire] = field(default_factory=list)
+    vias: list[WiringVia] = field(default_factory=list)
     #: bounding-box boundary shape (layer ``pcb``), if present
     boundary: Shape | None = None
     #: outline shapes (layer ``signal``)

src/freeroute/dsn/reader.py

@@ -9,6 +9,8 @@ tolerant ``skip_scope`` behaviour.
 
 from __future__ import annotations
 
+import re
+
 from .model import (
     ClearanceRule,
     ComponentPlace,
@@ -25,6 +27,8 @@ from .model import (
     Pin,
     Resolution,
     WidthRule,
+    WiringVia,
+    WiringWire,
 )
 from .sexp import SExp, parse
 from .shapes import Shape, read_area, read_shape
@@ -178,6 +182,16 @@ def _read_structure(node: SExp, board: DsnBoard) -> None:
             area = read_area(it)
             if area is not None:
                 board.keepouts.append(Keepout(area=area, kind="via_keepout"))
+        elif head == "wire_keepout":
+            # KiCad writes a "no tracks" rule area this way (vias allowed).
+            area = read_area(it)
+            if area is not None:
+                board.keepouts.append(Keepout(area=area, kind="wire_keepout"))
+        elif head == "plane":
+            # (plane <net> <shape>): KiCad exports each zone this way
+            plane = _read_plane(it)
+            if plane is not None:
+                board.planes.append(plane)
         elif head == "place_keepout":
             area = read_area(it)
             if area is not None:
@@ -285,6 +299,10 @@ def _read_image(node: SExp) -> Image | None:
             area = read_area(it)
             if area is not None:
                 image.via_keepouts.append(area)
+        elif head == "wire_keepout":
+            area = read_area(it)
+            if area is not None:
+                image.wire_keepouts.append(area)
         elif head == "place_keepout":
             area = read_area(it)
             if area is not None:
@@ -467,12 +485,26 @@ def _read_network(node: SExp, board: DsnBoard) -> None:
 # --- top level ---------------------------------------------------------------
 
 
+_STRING_QUOTE = re.compile(r"\(\s*string_quote\s+(\S)\s*\)")
+
+
+def _declared_quote(text: str) -> str:
+    """The quote character the file declares in ``(string_quote X)``.
+
+    Only that character opens a string. Without a declaration both kinds are
+    accepted, as before: KiCad declares ``"`` and then writes a bare ``'``
+    where a value is a single quote mark, e.g. a keycap part number.
+    """
+    found = _STRING_QUOTE.search(text[:4096])
+    return found.group(1) if found else "\"'"
+
+
 def parse_dsn(text: str) -> DsnBoard:
     """Parse DSN ``text`` into a :class:`DsnBoard`.
 
     Raises :class:`DsnParseError` if the top-level scope is not ``(pcb ...)``.
     """
-    top = parse(text)
+    top = parse(text, _declared_quote(text))
     if top.head != "pcb":
         raise DsnParseError(
             f"not a Specctra DSN file: expected top-level '(pcb ...)', got '({top.head} ...)'"
@@ -501,6 +533,56 @@ def parse_dsn(text: str) -> DsnBoard:
             _read_placement(it, board)
         elif head == "network":
             _read_network(it, board)
-        # `wiring` and unknown scopes are intentionally ignored for now.
+        elif head == "wiring":
+            _read_wiring(it, board)
+        # unknown scopes are ignored
 
     return board
+
+
+def _read_wiring(node: SExp, board: DsnBoard) -> None:
+    """Tracks and vias already on the board. They stay where they are: the
+    router treats them as copper of their net that other nets keep clear of."""
+    for it in node.items:
+        if not isinstance(it, SExp):
+            continue
+        net_scope = it.child("net")
+        net = _first_value(net_scope) if net_scope is not None else None
+        if not net:
+            continue  # netless copper would need a keepout, not a wire
+        if it.head == "wire":
+            path = it.child("path") or it.child("polyline_path")
+            vals = [v.text for v in path.values()] if path is not None else []
+            if len(vals) < 6:
+                continue
+            try:
+                width = float(vals[1])
+                coords = [float(v) for v in vals[2:]]
+            except ValueError:
+                continue
+            board.wires.append(WiringWire(net=net, layer=vals[0], width=width, coords=coords))
+        elif it.head == "via":
+            vals = [v.text for v in it.values()]
+            if len(vals) < 3:
+                continue
+            try:
+                x, y = float(vals[1]), float(vals[2])
+            except ValueError:
+                continue
+            board.vias.append(WiringVia(net=net, padstack=vals[0], x=x, y=y))
+
+
+def _read_plane(node: SExp):
+    """``(plane <net> (polygon <layer> <width> x y ...))`` -> :class:`Plane`."""
+    from .model import Plane
+
+    items = node.items
+    if not items or not isinstance(items[0], Token):
+        return None
+    net = items[0].text
+    for sub in items[1:]:
+        if isinstance(sub, SExp):
+            shape = read_shape(sub)
+            if shape is not None:
+                return Plane(net=net, shape=shape)
+    return None

src/freeroute/geometry/__init__.py

@@ -21,7 +21,7 @@ from .direction import Direction, IntDirection
 from .float_point import FloatPoint
 from .limits import CRIT_DOUBLE, CRIT_INT
 from .line import Line
-from .octagon import ceil_sqrt2, overlaps_2d, segment_octagon
+from .octagon import ceil_sqrt2, overlaps_2d, segment_octagon, segment_slab
 from .point import IntPoint, Point, RationalPoint, point, rational_point
 from .polygon import Polygon
 from .polygon_shape import PolygonShape
@@ -59,5 +59,6 @@ __all__ = [
     "shove_segment",
     "ceil_sqrt2",
     "segment_octagon",
+    "segment_slab",
     "overlaps_2d",
 ]

src/freeroute/geometry/octagon.py

@@ -29,7 +29,7 @@ from .line import Line
 from .point import IntPoint
 from .simplex import Simplex
 
-__all__ = ["ceil_sqrt2", "segment_octagon", "overlaps_2d"]
+__all__ = ["ceil_sqrt2", "segment_octagon", "segment_slab", "overlaps_2d"]
 
 
 def ceil_sqrt2(radius: int) -> int:
@@ -82,6 +82,46 @@ def segment_octagon(a: IntPoint, b: IntPoint, radius: int) -> Simplex:
     return Simplex.get_instance(lines)
 
 
+def segment_slab(a: IntPoint, b: IntPoint, radius: int) -> Simplex:
+    """Convex cover of segment ``a``-``b`` swept by ``radius``, at any angle.
+
+    The rectangle along the segment, ``radius`` either side, with flush ends
+    like :func:`polyline.segment_box`: the ends of a trace leg sit on a pad or
+    on the square corner tile of the next leg, which cover them. Corners are
+    rounded away from the middle and the radius gets one unit more, so the
+    side bounds never under-report, and it stays tight for a slanted segment
+    off the 45-degree lines (a pin leaving along its pad's axis on a part
+    turned 30 degrees).
+    """
+    dx, dy = b.x - a.x, b.y - a.y
+    length = math.hypot(dx, dy)
+    r = max(radius, 0) + 1
+    if length == 0:
+        return Simplex.from_corners([
+            IntPoint(a.x - r, a.y - r), IntPoint(a.x + r, a.y - r),
+            IntPoint(a.x + r, a.y + r), IntPoint(a.x - r, a.y + r),
+        ])
+    ux, uy = dx / length, dy / length
+    nx, ny = -uy, ux
+    mx, my = (a.x + b.x) / 2, (a.y + b.y) / 2
+
+    def out(x: float, y: float) -> IntPoint:
+        return IntPoint(math.ceil(x) if x >= mx else math.floor(x),
+                        math.ceil(y) if y >= my else math.floor(y))
+
+    corners = [
+        out(a.x + nx * r, a.y + ny * r),
+        out(b.x + nx * r, b.y + ny * r),
+        out(b.x - nx * r, b.y - ny * r),
+        out(a.x - nx * r, a.y - ny * r),
+    ]
+    for winding in (corners, corners[::-1]):
+        slab = Simplex.from_corners(winding)
+        if not slab.is_empty():
+            return slab
+    return Simplex(())
+
+
 def overlaps_2d(shape_a, shape_b) -> bool:
     """True if the two convex tiles share 2-D area (a real clearance overlap).
 

src/freeroute/route/exact_router.py

@@ -31,17 +31,20 @@ from dataclasses import dataclass, field
 import math
 
 from freeroute.board.board import BasicBoard
-from freeroute.board.items import Pin
+from freeroute.board.items import Pin, Via
 from freeroute.board.search_tree import ShapeSearchTree, TreeShape
 from freeroute.geometry import (
     IntBox,
     IntPoint,
     Polyline,
     PolylineShape,
+    Simplex,
     segment_box,
     segment_octagon,
+    segment_slab,
     shove_segment,
 )
+from freeroute.geometry.polyline import corner_box
 
 from .grid_router import RouteResult, route_board
 
@@ -90,6 +93,21 @@ def route_board_exact(
     diagonal: bool = False,
     max_shove_depth: int = 5,
     shove_cap: int = 3,
+    via_half: int | None = None,
+    edge_clearance: int | None = None,
+    resolution: int = 1,
+    heuristic_weight: float = 1.0,
+    seed: int | None = None,
+    route_first: frozenset | None = None,
+    access_cost: float = 0.0,
+    negotiate: int = 0,
+    rollback: bool = True,
+    tree_nets: bool = True,
+    net_widths: dict[int, int] | None = None,
+    via_drill: int | None = None,
+    hole_to_hole: int = 0,
+    only_nets: frozenset | None = None,
+    bounds: IntBox | None = None,
 ) -> ExactRouteResult:
     """Route ``board`` orthogonally and verify the result with exact geometry.
 
@@ -102,6 +120,7 @@ def route_board_exact(
         i for i, layer in enumerate(board.layer_structure.arr) if layer.is_signal
     ]
     half_width = max(trace_width // 2, 1)
+    via_half = via_half or half_width
     step = trace_width + clearance
 
     result = route_board(
@@ -113,7 +132,24 @@ def route_board_exact(
         max_passes=max_passes,
         rip_up=rip_up,
         orthogonal=True,
+        via_half=via_half,
+        edge_clearance=edge_clearance,
+        resolution=resolution,
+        heuristic_weight=heuristic_weight,
+        seed=seed,
+        route_first=route_first,
+        access_cost=access_cost,
+        negotiate=negotiate,
+        rollback=rollback,
+        tree_nets=tree_nets,
+        net_widths=net_widths,
+        via_drill=via_drill,
+        hole_to_hole=hole_to_hole,
+        only_nets=only_nets,
+        bounds=bounds,
     )
+    edge = 0 if edge_clearance is None else edge_clearance
+    outline = board.outline
 
     tree = ShapeSearchTree()
     owner = _counter()
@@ -128,37 +164,109 @@ def route_board_exact(
         net = pin.net_nos[0] if pin.net_nos else -1
         pin_layers = frozenset(layer for layer in pin.layers if layer in signal_layers)
         if pin_layers:
-            tree.insert(TreeShape(next(owner), net, pin_layers, box))
+            # a rotated pad is checked against its outline, not its box
+            exact = pin.shape if _is_rotated(pin.shape) else None
+            tree.insert(TreeShape(next(owner), net, pin_layers, box, exact=exact))
+    for net, copper_layers, box in board.get_fixed_copper():
+        on = frozenset(layer for layer in copper_layers if layer in signal_layers)
+        if on and not box.is_empty():
+            tree.insert(TreeShape(next(owner), net, on, box))
     for obstacle in board.get_obstacle_areas():
         if obstacle.layer not in signal_layers:
             continue
+        blocks = (
+            "all" if obstacle.blocks_wires and obstacle.blocks_vias
+            else "wires" if obstacle.blocks_wires else "vias"
+        )
         for tile in obstacle.tiles:
             box = tile.bounding_box()
             if not box.is_empty():
-                tree.insert(TreeShape(next(owner), -1, frozenset({obstacle.layer}), box))
+                tree.insert(
+                    TreeShape(
+                        next(owner), -1, frozenset({obstacle.layer}), box,
+                        blocks=blocks, clearance=obstacle.clearance,
+                    )
+                )
 
     via_layers = frozenset(signal_layers)
     accepted: dict[int, _Accepted] = {}
+    fixed_vias = {
+        (item.net_nos[0], item.location)
+        for item in board.get_items()
+        if isinstance(item, Via) and item.fixed and item.net_nos
+    }
 
-    for net_no in sorted(set(result.wires) | set(result.vias)):
-        boxes = _net_boxes(result, net_no, half_width, via_layers)
-        if any(
-            tree.clearance_conflict(box, net_no, layer, clearance)
-            for box, box_layers in boxes
-            for layer in box_layers
+    # Verify connection by connection, so one conflicting segment of a
+    # 25-pin supply net costs that one connection, not the whole net.
+    rejected: list[tuple[int, str, str]] = []
+    ends_list = result.connection_ends or [("?", "?", "")] * len(result.connections)
+    anchors_list = getattr(result, "connection_anchors", None) or [()] * len(result.connections)
+    # each net is checked at the width it will be written at: its class's
+    # when all of its connections went in at that, else the default
+    net_half = dict(result.net_half)
+    # a connection that ended on another's copper (a T into its net's tree)
+    # dangles if that one is dropped, so it is dropped too; connections come
+    # in commit order, anchors first
+    dropped_at: set[int] = set()
+    for pos, ((net_no, wires, vias), ends, anchors) in sorted(
+        enumerate(zip(result.connections, ends_list, anchors_list, strict=False)),
+        key=lambda c: c[1][0][0],
     ):
+        if any(a in dropped_at for a in anchors):
+            dropped_at.add(pos)
+            rejected.append((net_no, *ends))
+            continue
+        wire_half = net_half.get(net_no, half_width)
+        pieces = _copper_pieces(wires, vias, wire_half, via_layers, via_half)
+        boxes = [(box, box_layers) for box, box_layers, _ in pieces]
+        wire_count = len(_copper_pieces(wires, [], wire_half, via_layers, via_half))
+        if any(
+            (
+                tree.segment_conflict(*seg, wire_half, net_no, layer, clearance)
+                if seg is not None
+                else tree.clearance_conflict(
+                    box, net_no, layer, clearance, "wire" if i < wire_count else "via"
+                )
+            )
+            for i, (box, box_layers, seg) in enumerate(pieces)
+            for layer in box_layers
+        ) or _end_in_rule_area(tree, wires, wire_half) or (
+            outline is not None and not _inside_outline(
+                outline, boxes[:wire_count], vias, (via_half or wire_half) + edge, edge
+            )
+        ):
+            rejected.append((net_no, *ends))
+            dropped_at.add(pos)
             continue  # exact-clearance conflict -> drop (may be recovered by shove)
-        acc = _Accepted(wires=result.wires.get(net_no, []), vias=result.vias.get(net_no, []))
-        for box, box_layers in boxes:
+        acc = accepted.get(net_no)
+        if acc is None:
+            acc = accepted[net_no] = _Accepted(wires=[], vias=[])
+        acc.wires.extend(wires)
+        # connections of one net that end on the same plane cell share its
+        # via: write it once, and never on top of a via already on the board
+        acc.vias.extend(
+            v for v in dict.fromkeys(vias)
+            if v not in acc.vias and not _on_fixed_via(net_no, v, fixed_vias, via_half)
+        )
+        for box, box_layers, seg in pieces:
             oid = next(owner)
+            if seg is None:
                 tree.insert(TreeShape(oid, net_no, box_layers, box, routed=True))
+            else:  # a slanted pin exit: its exact copper, rebuilt for the DRC check
+                tree.insert(TreeShape(
+                    oid, net_no, box_layers, box, routed=True,
+                    exact=segment_slab(*seg, wire_half), seg=("slab", *seg, wire_half),
+                ))
             acc.owners.append(oid)
-        accepted[net_no] = acc
 
+    accepted_before_recovery = set(accepted)
     # 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
     # copper conflicted.
-    dropped = sorted(_routable_nets(board, signal_layers) - set(accepted))
+    routable = _routable_nets(board, signal_layers)
+    if only_nets is not None:  # a window re-route: the other nets are not ours to route
+        routable &= set(only_nets)
+    dropped = sorted(routable - set(accepted))
 
     shoves = 0
     if shove and dropped:
@@ -183,15 +291,32 @@ def route_board_exact(
 
     if diagonal:
         outline = board.bounding_box
-        for net_no in sorted(_routable_nets(board, signal_layers)):
+        for net_no in sorted(routable):
             _diagonalize(
                 net_no, board, tree, accepted, owner, signal_layers, half_width, clearance, outline
             )
 
     clean = RouteResult(half_width)
+    # what is still missing: what the grid could not route, plus what the
+    # exact check rejected, less any net shove or the diagonal pass recovered
+    clean.failed = [
+        *result.failed,
+        *(r for r in rejected if not (r[0] in accepted and r[0] not in accepted_before_recovery)),
+    ]
     for net_no, acc in accepted.items():
         clean.wires[net_no] = acc.wires
         clean.vias[net_no] = acc.vias
+    # shove and the diagonal pass lay copper at the default width: nets they
+    # recovered, and nets whose traces shove pushed aside
+    reshaped = (set(accepted) - accepted_before_recovery) | {
+        net for net, acc in accepted.items() if acc.shove_count
+    }
+    if diagonal:
+        reshaped = set(accepted)
+    clean.net_half = {
+        net: half for net, half in net_half.items() if net in accepted and net not in reshaped
+    }
+    clean.narrowed = list(result.narrowed)
 
     drc_clean = tree.has_violation(clearance) is None
     return ExactRouteResult(result=clean, tree=tree, drc_clean=drc_clean, shoves=shoves)
@@ -543,19 +668,78 @@ def _rollback(shoved, accepted, tree, owner) -> int:  # noqa: ARG001
 # --- helpers -----------------------------------------------------------------
 
 
-def _net_boxes(result, net_no, half_width, via_layers):
+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 _end_in_rule_area(tree, wires, half_width) -> bool:
+    """A wire's tiles stop at its end points, but a track ends in a round cap
+    half its width beyond them. Against other copper the pad or via there
+    covers it; a rule area has no clearance to absorb it, so check it."""
+    for layer, points in wires:
+        for end in (points[0], points[-1]):
+            if tree.rule_area_overlap(corner_box(end, half_width), layer):
+                return True
+    return False
+
+
+def _on_fixed_via(net_no, point, fixed_vias, via_half) -> bool:
+    """A routed via that reuses a via already on the board: the grid put it
+    on the fixed via's cell, a little off its centre, and it is not written."""
+    return any(
+        net == net_no and abs(loc.x - point.x) <= via_half and abs(loc.y - point.y) <= via_half
+        for net, loc in fixed_vias
+    )
+
+
+def _copper_pieces(wires, vias, half_width, via_layers, via_half=None):
+    """Like :func:`_copper_boxes`, but a slanted wire segment (a pin leaving
+    along a turned pad's axis) comes with its end points, so it can be checked
+    on its exact copper: ``(box, layers, (a, b) or None)``."""
+    via_half = via_half or half_width
+    pieces: list[tuple[IntBox, frozenset[int], tuple | None]] = []
+    for layer, points in wires:
+        on = frozenset({layer})
+        for a, b in zip(points, points[1:], strict=False):
+            if a.x == b.x or a.y == b.y:
+                pieces.append((segment_box(a, b, half_width), on, None))
+            else:
+                pieces.append((segment_slab(a, b, half_width).bounding_box(), on, (a, b)))
+        for c in points[1:-1]:
+            pieces.append((corner_box(c, half_width), on, None))
+    for loc in vias:
+        vbox = IntBox(loc.x - via_half, loc.y - via_half, loc.x + via_half, loc.y + via_half)
+        pieces.append((vbox, via_layers, None))
+    return pieces
+
+
+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, []):
-        vbox = IntBox(
-            loc.x - half_width, loc.y - half_width, loc.x + half_width, loc.y + half_width
-        )
+    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
 
 
+def _inside_outline(outline, wire_boxes, vias, via_reach, edge) -> bool:
+    """Copper inside the board, ``edge`` from its outline. A via is round, as
+    the grid and KiCad take it: its square box would reach past a chamfered
+    corner where the via itself does not."""
+    return all(outline.box_clear(b, edge) for b, _ in wire_boxes) and all(
+        outline.point_clear(v, via_reach) for v in vias
+    )
+
+
+def _is_rotated(shape) -> bool:
+    return isinstance(shape, Simplex) and not shape.is_int_box()
+
+
 def _net_pins(board: BasicBoard, net_no: int, signal_layers) -> list[Pin]:
     return [
         pin

src/freeroute/route/orders.py

@@ -0,0 +1,98 @@
+"""Route one board in several connection orders at once and keep the best.
+
+Which connection routes first moves the result on a crowded board by several
+connections either way, and no single order wins everywhere. Routing a few
+orders in parallel processes and keeping the one that leaves the fewest
+connections unrouted costs cores, not wall time.
+
+Without a seed the candidates are the default order and seeds 0 to N-2, so the
+result is never worse than a plain run. With seed S they are seeds S to S+N-1.
+Ties go to the earlier candidate, so the choice is deterministic.
+"""
+
+from __future__ import annotations
+
+from concurrent.futures import ProcessPoolExecutor
+import os
+
+from freeroute.dsn import parse_dsn
+from freeroute.ses import RoutingResult
+
+from .pipeline import build_exact_routing_result, build_routing_result
+
+
+def candidate_seeds(orders: int, seed: int | None = None) -> list[int | None]:
+    orders = max(int(orders), 1)
+    if seed is None:
+        return [None, *range(orders - 1)]
+    return list(range(seed, seed + orders))
+
+
+def score(result: RoutingResult) -> tuple[int, int]:
+    """Connections left open, then those left to a zone fill: lower is better."""
+    missing = sum(1 for u in result.unrouted if not u[3])
+    return missing, len(result.unrouted) - missing
+
+
+def route_once(dsn_text: str, engine: str, options: dict, seed: int | None) -> RoutingResult:
+    dsn = parse_dsn(dsn_text)
+    if engine == "exact":
+        return build_exact_routing_result(dsn, seed=seed, **options)
+    if engine == "grid":
+        return build_routing_result(dsn, seed=seed, **options)
+    raise ValueError(f"routing orders are not supported by the {engine} engine")
+
+
+def best_of_orders(
+    dsn_text: str,
+    engine: str,
+    options: dict,
+    *,
+    orders: int,
+    seed: int | None = None,
+    jobs: int | None = None,
+) -> tuple[RoutingResult, int | None, list[tuple[int | None, tuple[int, int]]]]:
+    """Route ``orders`` orders and return the best result, the seed that made
+    it (None for the default order), and every candidate's seed and score."""
+    seeds = candidate_seeds(orders, seed)
+    if len(seeds) == 1:
+        result = route_once(dsn_text, engine, options, seeds[0])
+        return result, seeds[0], [(seeds[0], score(result))]
+    jobs = max(1, min(jobs or os.cpu_count() or 1, len(seeds)))
+    with ProcessPoolExecutor(jobs) as pool:
+        futures = [pool.submit(route_once, dsn_text, engine, options, s) for s in seeds]
+        results = [f.result() for f in futures]
+    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

@@ -12,6 +12,9 @@ to DSN units (dividing by the resolution) for the SES ``(wire (path ...))`` and
 
 from __future__ import annotations
 
+import re
+import time
+
 from freeroute.board import build_board
 from freeroute.dsn import DsnBoard, parse_dsn
 from freeroute.ses import RoutedVia, RoutedWire, RoutingResult, write_ses
@@ -19,6 +22,7 @@ from freeroute.ses import RoutedVia, RoutedWire, RoutingResult, write_ses
 from .exact_router import ExactRouteResult, route_board_exact
 from .grid_router import RouteResult, route_board
 from .room_router import route_board_rooms
+from .window import window_reroute as window_reroute_stage
 
 __all__ = ["route", "route_dsn_board", "build_routing_result"]
 
@@ -34,6 +38,25 @@ def _rule_width_dsn(dsn: DsnBoard) -> float:
     return rules[0].value if rules else _DEFAULT_WIDTH_DSN
 
 
+def _net_widths_board(dsn: DsnBoard, scale: int) -> dict[int, int]:
+    """Track width of every net whose class asks for more than the default,
+    in board units, by net number (build_board numbers nets in DSN order)."""
+    default = _rule_width_dsn(dsn)
+    by_name: dict[str, float] = {}
+    for net_class in dsn.net_classes:
+        if not net_class.width_rules:
+            continue
+        width = net_class.width_rules[0].value
+        if width > default:
+            for name in net_class.net_names:
+                by_name[name] = max(by_name.get(name, 0.0), width)
+    return {
+        i + 1: round(by_name[net.name] * scale)
+        for i, net in enumerate(dsn.nets)
+        if net.name in by_name
+    }
+
+
 def _rule_clearance_dsn(dsn: DsnBoard) -> float:
     for rule in dsn.structure_rules.clearance_rules:
         if not rule.class_pairs:  # the layer-wide default clearance
@@ -45,12 +68,62 @@ 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_drill_board(dsn: DsnBoard, scale: int) -> int | None:
+    """The via's drill in board units, from KiCad's padstack name
+    (``Via[0-1]_600:300_um`` is a 600 um pad with a 300 um drill); None when
+    the name does not say, and the pad size stands in for it."""
+    match = re.search(r"_([\d.]+):([\d.]+)_um", _via_padstack(dsn))
+    if not match:
+        return None
+    return round(float(match.group(2)) * _dsn_units_per_um(dsn) * scale)
+
+
+def _dsn_units_per_um(dsn: DsnBoard) -> float:
+    return {"um": 1.0, "mm": 0.001, "mil": 1 / 25.4, "inch": 1 / 25400}.get(dsn.unit, 1.0)
+
+
+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.
+
+    None when the DSN names no via padstack with a shape, so the engines fall
+    back to their old estimate.
+    """
+    padstack = dsn.padstack(_via_padstack(dsn))
+    if padstack is None or not padstack.shapes:
+        return None
+    half = 0.0
+    for shape in padstack.shapes:
+        if hasattr(shape, "diameter"):
+            half = max(half, shape.diameter / 2)
+        elif len(getattr(shape, "coords", [])) >= 4:
+            xs, ys = shape.coords[0::2], shape.coords[1::2]
+            half = max(half, (max(xs) - min(xs)) / 2, (max(ys) - min(ys)) / 2)
+    return round(half * scale) or None
+
+
 def route_dsn_board(
     dsn: DsnBoard,
     *,
+    resolution: int = 1,
+    edge_clearance_mm: float | None = None,
     layers: list[int] | None = None,
     rip_up: bool = True,
     max_passes: int = 10,
+    seed: int | None = None,
+    route_first: frozenset | None = None,
+    access_cost: float = 0.0,
+    negotiate: int = 0,
+    hole_to_hole_mm: float = 0.25,
+    rollback: bool = True,
+    tree_nets: bool = True,
 ) -> 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
@@ -58,15 +131,28 @@ 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,
+        resolution=resolution,
+        via_half=_via_half_board(dsn, scale),
+        edge_clearance=edge_clearance_board,
         trace_width=width_board,
         clearance=clearance_board,
         layers=layers,
         rip_up=rip_up,
         max_passes=max_passes,
+        seed=seed,
+        route_first=route_first,
+        access_cost=access_cost,
+        negotiate=negotiate,
+        rollback=rollback,
+        tree_nets=tree_nets,
+        net_widths=_net_widths_board(dsn, scale),
+        via_drill=_via_drill_board(dsn, scale),
+        hole_to_hole=_mm_to_board(dsn, scale, hole_to_hole_mm) or 0,
     )
     return result, scale, [layer.name for layer in dsn.layers]
 
@@ -81,6 +167,9 @@ def _to_routing_result(route, dsn: DsnBoard, scale: int, layer_names: list[str])
     result = RoutingResult()
     for net_no, segments in route.wires.items():
         name = numbers_to_names.get(net_no, str(net_no))
+        # its class's width when every connection of the net went in at it
+        half = getattr(route, "net_half", {}).get(net_no)
+        net_width = 2 * half / scale if half else width_dsn
         for layer_index, path in segments:
             layer_name = layer_names[layer_index] if layer_index < len(layer_names) else "F.Cu"
             coords: list[float] = []
@@ -88,24 +177,46 @@ def _to_routing_result(route, dsn: DsnBoard, scale: int, layer_names: list[str])
                 coords.append(point.x / scale)
                 coords.append(point.y / scale)
             if len(coords) >= 4:
-                result.add_wire(name, RoutedWire(layer=layer_name, width=width_dsn, coords=coords))
+                result.add_wire(name, RoutedWire(layer=layer_name, width=net_width, coords=coords))
     for net_no, locations in route.vias.items():
         name = numbers_to_names.get(net_no, str(net_no))
         for loc in locations:
             result.add_via(name, RoutedVia(padstack=via_name, x=loc.x / scale, y=loc.y / scale))
+    result.unrouted = [
+        (numbers_to_names.get(n, str(n)), a, b, zone) for n, a, b, zone in getattr(route, "failed", [])
+    ]
+    result.narrowed = [
+        (numbers_to_names.get(n, str(n)), a, b) for n, a, b in getattr(route, "narrowed", [])
+    ]
     return result
 
 
 def build_routing_result(
     dsn: DsnBoard,
     *,
+    resolution: int = 1,
     layers: list[int] | None = None,
     rip_up: bool = True,
     max_passes: int = 10,
+    edge_clearance_mm: float | None = None,
+    seed: int | None = None,
+    route_first: frozenset | None = None,
+    access_cost: float = 0.0,
+    negotiate: int = 0,
+    hole_to_hole_mm: float = 0.25,
+    rollback: bool = True,
+    tree_nets: bool = True,
 ) -> 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, resolution=resolution, seed=seed,
+        route_first=route_first,
+        access_cost=access_cost,
+        negotiate=negotiate,
+        hole_to_hole_mm=hole_to_hole_mm,
+        rollback=rollback,
+        tree_nets=tree_nets,
     )
     return _to_routing_result(route, dsn, scale, layer_names)
 
@@ -113,11 +224,26 @@ def build_routing_result(
 def route_dsn_board_exact(
     dsn: DsnBoard,
     *,
+    resolution: int = 1,
+    heuristic_weight: float = 1.0,
+    edge_clearance_mm: float | None = None,
     layers: list[int] | None = None,
     max_passes: int = 10,
     rip_up: bool = True,
     shove: bool = False,
     diagonal: bool = False,
+    seed: int | None = None,
+    route_first: frozenset | None = None,
+    access_cost: float = 0.0,
+    negotiate: int = 0,
+    hole_to_hole_mm: float = 0.25,
+    rollback: bool = True,
+    tree_nets: bool = True,
+    window_reroute: int = 0,
+    window_resolution: int = 4,
+    window_margin_mm: float = 1.5,
+    window_budget: float = 0.25,
+    window_cap: int = 40,
 ) -> 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.
@@ -126,17 +252,50 @@ 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)
+    # the settings a window re-route repeats, at its own resolution
+    common = {
+        "heuristic_weight": heuristic_weight,
+        "via_half": _via_half_board(dsn, scale),
+        "edge_clearance": edge_clearance_board,
+        "trace_width": width_board,
+        "clearance": clearance_board,
+        "layers": layers,
+        "max_passes": max_passes,
+        "rip_up": rip_up,
+        "shove": shove,
+        "diagonal": diagonal,
+        "rollback": rollback,
+        "tree_nets": tree_nets,
+        "net_widths": _net_widths_board(dsn, scale),
+        "via_drill": _via_drill_board(dsn, scale),
+        "hole_to_hole": _mm_to_board(dsn, scale, hole_to_hole_mm) or 0,
+    }
+    started = time.monotonic()
     exact = route_board_exact(
         board,
-        trace_width=width_board,
-        clearance=clearance_board,
-        layers=layers,
-        max_passes=max_passes,
-        rip_up=rip_up,
-        shove=shove,
-        diagonal=diagonal,
+        resolution=resolution,
+        seed=seed,
+        route_first=route_first,
+        access_cost=access_cost,
+        negotiate=negotiate,
+        **common,
+    )
+    if window_reroute > 0:
+        via_half = common["via_half"] or max(width_board // 2, 1)
+        exact.result = window_reroute_stage(
+            dsn, exact.result, common,
+            rounds=window_reroute,
+            resolution=max(int(window_resolution), resolution),
+            margin=_mm_to_board(dsn, scale, window_margin_mm) or 0,
+            via_half=via_half,
+            via_drill=common["via_drill"] or 2 * via_half,
+            via_name=_via_padstack(dsn),
+            # a share of what the routing itself took
+            budget_s=max(float(window_budget), 0.0) * (time.monotonic() - started),
+            max_windows=window_cap,
         )
     return exact, scale, [layer.name for layer in dsn.layers]
 
@@ -144,11 +303,26 @@ def route_dsn_board_exact(
 def build_exact_routing_result(
     dsn: DsnBoard,
     *,
+    resolution: int = 1,
+    heuristic_weight: float = 1.0,
     layers: list[int] | None = None,
     shove: bool = False,
     diagonal: bool = False,
     rip_up: bool = True,
     max_passes: int = 10,
+    edge_clearance_mm: float | None = None,
+    seed: int | None = None,
+    route_first: frozenset | None = None,
+    access_cost: float = 0.0,
+    negotiate: int = 0,
+    hole_to_hole_mm: float = 0.25,
+    rollback: bool = True,
+    tree_nets: bool = True,
+    window_reroute: int = 0,
+    window_resolution: int = 4,
+    window_margin_mm: float = 1.5,
+    window_budget: float = 0.25,
+    window_cap: int = 40,
 ) -> RoutingResult:
     """Route ``dsn`` (exact track) and convert to a DSN-unit RoutingResult."""
     exact, scale, layer_names = route_dsn_board_exact(
@@ -158,12 +332,32 @@ def build_exact_routing_result(
         diagonal=diagonal,
         rip_up=rip_up,
         max_passes=max_passes,
+        edge_clearance_mm=edge_clearance_mm,
+        resolution=resolution,
+        heuristic_weight=heuristic_weight,
+        seed=seed,
+        route_first=route_first,
+        access_cost=access_cost,
+        negotiate=negotiate,
+        hole_to_hole_mm=hole_to_hole_mm,
+        rollback=rollback,
+        tree_nets=tree_nets,
+        window_reroute=window_reroute,
+        window_resolution=window_resolution,
+        window_margin_mm=window_margin_mm,
+        window_budget=window_budget,
+        window_cap=window_cap,
     )
     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-
@@ -171,10 +365,13 @@ 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,
@@ -185,10 +382,17 @@ 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)
 
 
@@ -200,6 +404,8 @@ def route(
     shove: bool = False,
     pack: bool = False,
     diagonal: bool = False,
+    edge_clearance_mm: float | None = None,
+    resolution: int = 1,
 ) -> str:
     """Route a Specctra DSN string and return the routed SES string.
 
@@ -213,9 +419,16 @@ 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, resolution=resolution,
+        )
     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, resolution=resolution
+        )
     return write_ses(dsn, result)

src/freeroute/route/room_router.py

@@ -471,6 +471,8 @@ def route_board_rooms(
     pack: bool = False,
     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.
 
@@ -494,6 +496,10 @@ def route_board_rooms(
         i for i, layer in enumerate(board.layer_structure.arr) if layer.is_signal
     ]
     half_width = max(trace_width // 2, 1)
+    # 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
 
@@ -509,6 +515,10 @@ def route_board_rooms(
         pin_layers = frozenset(layer for layer in pin.layers if layer in signal_layers)
         if pin_layers:
             tree.insert(TreeShape(next(owner), net, pin_layers, box))
+    for net, copper_layers, box in board.get_fixed_copper():
+        on = frozenset(layer for layer in copper_layers if layer in signal_layers)
+        if on and not box.is_empty():
+            tree.insert(TreeShape(next(owner), net, on, box))
     for obstacle in board.get_obstacle_areas():
         if obstacle.layer not in signal_layers:
             continue
@@ -537,7 +547,7 @@ def route_board_rooms(
             via_layers,
             accepted,
             shove,
-        )
+        via_half=via_half, edge=edge)
     for net_no in sorted(_routable_nets(board, signal_layers)):
         if net_no in packed:
             continue
@@ -562,7 +572,7 @@ def route_board_rooms(
                 accepted,
                 max_shove_depth,
                 shove_cap,
-            )
+            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)
@@ -587,6 +597,8 @@ def _route_connection(
     accepted=None,
     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)
@@ -607,7 +619,7 @@ def _route_connection(
 
     if realized is not None:
         wires, vias = realized
-        boxes = _collect_boxes(wires, vias, half_width, via_layers, outline)
+        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
@@ -615,7 +627,7 @@ def _route_connection(
         ):
             _commit(
                 net_no, wires, vias, tree, result, owner, half_width, via_layers, shove, accepted
-            )
+            , via_half=via_half)
             return 0
 
     # the net would be dropped: try a transactional shove-in-rooms recovery
@@ -634,11 +646,12 @@ def _route_connection(
             clearance,
             max_shove_depth,
             shove_cap,
-        )
+        via_half=via_half, edge=edge)
     return 0
 
 
-def _collect_boxes(wires, vias, half_width, via_layers, outline):
+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)."""
     boxes: list[tuple[IntBox, frozenset[int]]] = []
@@ -646,16 +659,21 @@ def _collect_boxes(wires, vias, half_width, via_layers, outline):
         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(
-            loc.x - half_width, loc.y - half_width, loc.x + half_width, loc.y + half_width
+            loc.x - via_half, loc.y - via_half, loc.x + via_half, loc.y + via_half
         )
         boxes.append((vbox, via_layers))
     return boxes
 
 
-def _commit(net_no, wires, vias, tree, result, owner, half_width, via_layers, shove, accepted):
+def _commit(
+    net_no, wires, vias, tree, result, owner, half_width, via_layers, shove, accepted, via_half=None
+):
+    via_half = via_half or half_width
     """Insert a verified route's copper and record it in the routed output.
 
     With ``shove=False`` this is the foundation router's exact commit sequence.
@@ -668,7 +686,7 @@ def _commit(net_no, wires, vias, tree, result, owner, half_width, via_layers, sh
                 tree.insert(TreeShape(next(owner), net_no, frozenset({layer}), box, routed=True))
         for loc in vias:
             vbox = IntBox(
-                loc.x - half_width, loc.y - half_width, loc.x + half_width, loc.y + half_width
+                loc.x - via_half, loc.y - via_half, loc.x + via_half, loc.y + via_half
             )
             tree.insert(TreeShape(next(owner), net_no, via_layers, vbox, routed=True))
         for layer, corners in wires:
@@ -693,7 +711,7 @@ def _commit(net_no, wires, vias, tree, result, owner, half_width, via_layers, sh
         acc.wire_owners.append(w_owners)
     for loc in vias:
         vbox = IntBox(
-            loc.x - half_width, loc.y - half_width, loc.x + half_width, loc.y + half_width
+            loc.x - via_half, loc.y - via_half, loc.x + via_half, loc.y + via_half
         )
         oid = next(owner)
         tree.insert(TreeShape(oid, net_no, via_layers, vbox, routed=True))
@@ -854,6 +872,8 @@ def _pack_channels(
     via_layers,
     accepted,
     shove,
+    via_half=None,
+    edge=None,
 ) -> set[int]:
     """Coordinated multi-trace channel packing (opt-in pre-pass).
 
@@ -922,7 +942,7 @@ def _pack_channels(
                     spacing_min,
                     via_layers,
                     outline,
-                )
+                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:
@@ -937,7 +957,7 @@ def _pack_channels(
                         via_layers,
                         shove,
                         accepted,
-                    )
+                    via_half=via_half)
                     routed.add(net_no)
     return routed
 
@@ -958,6 +978,8 @@ def _pack_group(
     spacing_min,
     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
@@ -1014,7 +1036,7 @@ def _pack_group(
         if len(corners) < 2:
             return None
         wires = [(layer, corners)]
-        boxes = _collect_boxes(wires, [], half_width, via_layers, outline)
+        boxes = _collect_boxes(wires, [], half_width, via_layers, outline, via_half=via_half, edge=edge)
         if boxes is None:
             return None
         if any(
@@ -1049,6 +1071,8 @@ def _shove_recover_room(
     clearance,
     max_shove_depth,
     shove_cap,
+    via_half=None,
+    edge=None,
 ) -> int:
     """Recover a dropped net by nudging the committed trace(s) that block it.
 

src/freeroute/route/window.py

@@ -0,0 +1,248 @@
+"""Window re-route: a last stage for the connections still unrouted.
+
+Around each stuck connection a window is cut: the box of its two end pins
+plus a margin. Every net whose routed copper lies wholly inside it is
+ripped; everything else stays, as fixed copper. The window is then routed
+again on its own, on a finer grid than the whole board can afford, the
+stuck connection's net and the ripped nets only. The result is kept only
+if fewer connections are left unrouted than before; otherwise the board is
+as it was. Each round doubles the margin for the connections still stuck.
+
+It is a last stage, so it is kept cheap: a window's board holds only what
+the window needs (every pin and piece of copper of the nets it reroutes,
+so their connectivity is unchanged, and of the other items only those near
+the window), the smallest windows go first, at most ``max_windows`` run per
+round, and no new window starts once ``budget_s`` seconds are spent.
+
+What makes it differ from re-running the same search near the failure: the
+finer grid finds gaps the board's grid steps over, and the ripped nets go in
+again in a new order around the stuck one. A finer grid on the whole board
+costs routes elsewhere (its cells are slower and its order changes); inside
+a small window it only ever replaces what it can improve.
+"""
+
+from __future__ import annotations
+
+import time
+from typing import Any
+
+from freeroute.board import BasicBoard, build_board
+from freeroute.board.items import ObstacleArea, Pin, Trace, Via
+from freeroute.dsn import DsnBoard
+from freeroute.geometry import IntBox, IntPoint
+
+from .exact_router import route_board_exact
+from .grid_router import RouteResult
+
+Copper = tuple[list[tuple[int, list[IntPoint]]], list[IntPoint]]
+
+
+def _pin_labels(board) -> dict[tuple[int, str], IntPoint]:
+    """Each pin's location by (net, label), the label a failure names it by."""
+    found: dict[tuple[int, str], IntPoint] = {}
+    for pin in board.get_pins():
+        for net in pin.net_nos:
+            found.setdefault((net, f"{pin.component_ref}-{pin.name}"), pin.location)
+    return found
+
+
+def _end_point(labels, net: int, label: str) -> IntPoint | None:
+    """Where a failure's end is: the first pin its label names."""
+    return labels.get((net, label.split("/")[0]))
+
+
+def _inside(copper: Copper, window: IntBox) -> bool:
+    wires, vias = copper
+    points = [p for _layer, path in wires for p in path] + list(vias)
+    return bool(points) and all(
+        window.ll.x <= p.x <= window.ur.x and window.ll.y <= p.y <= window.ur.y for p in points
+    )
+
+
+def _item_box(item) -> IntBox | None:
+    if isinstance(item, (Pin, Via)):
+        return item.shape.bounding_box() if item.shape is not None else None
+    if isinstance(item, ObstacleArea):
+        return item.bounding_box()
+    if isinstance(item, Trace) and item.corners:
+        h = item.half_width
+        xs, ys = [p.x for p in item.corners], [p.y for p in item.corners]
+        return IntBox(min(xs) - h, min(ys) - h, max(xs) + h, max(ys) + h)
+    return None
+
+
+def _meets(box: IntBox | None, view: IntBox) -> bool:
+    return box is not None and box.ll.x <= view.ur.x and view.ll.x <= box.ur.x and (
+        box.ll.y <= view.ur.y and view.ll.y <= box.ur.y
+    )
+
+
+def _path_box(path: list[IntPoint], grow: int) -> IntBox:
+    xs, ys = [p.x for p in path], [p.y for p in path]
+    return IntBox(min(xs) - grow, min(ys) - grow, max(xs) + grow, max(ys) + grow)
+
+
+def _window_board(
+    base: BasicBoard, base_items: list, view: IntBox, affected: set[int],
+    copper: dict[int, Copper], keep: set[int], half: dict[int, int], default_half: int,
+    via_half: int, via_drill: int, layers: list[int], via_name: str,
+) -> BasicBoard:
+    """The board a window is routed on: the base board's items of the nets
+    being rerouted and those near ``view``, plus the routed copper being kept
+    (all of an affected net's, so its connectivity is the whole board's, and
+    of other nets only what is near ``view``), as fixed copper."""
+    board = BasicBoard(base.layer_structure, base.nets, base.clearance_matrix, base.bounding_box)
+    board.outline = base.outline
+    for item, box in base_items:
+        if (item.net_nos and item.net_nos[0] in affected) or _meets(box, view):
+            board.insert(item)
+    for net in keep:
+        wires, vias = copper.get(net, ([], []))
+        width = half.get(net, default_half)
+        mine = net in affected
+        for layer, path in wires:
+            if len(path) >= 2 and (mine or _meets(_path_box(path, width), view)):
+                board.insert(Trace(net_nos=[net], fixed=True, layer=layer, half_width=width, corners=list(path)))
+        for location in dict.fromkeys(vias):
+            shape = IntBox(location.x - via_half, location.y - via_half,
+                           location.x + via_half, location.y + via_half)
+            if mine or _meets(shape, view):
+                board.insert(Via(
+                    net_nos=[net], fixed=True, padstack_name=via_name, drill=via_drill,
+                    location=location, layers=list(layers), shape=shape,
+                ))
+    return board
+
+
+def _open(failed) -> list:
+    """Failures that are real opens, not connections left to a zone fill."""
+    return [f for f in failed if not (len(f) > 3 and f[3])]
+
+
+def window_reroute(
+    dsn: DsnBoard,
+    result: RouteResult,
+    route_args: dict[str, Any],
+    *,
+    rounds: int,
+    resolution: int,
+    margin: int,
+    via_half: int,
+    via_drill: int,
+    via_name: str,
+    budget_s: float | None = None,
+    max_windows: int = 40,
+) -> RouteResult:
+    """Re-route a window around each still-failing connection; keep only gains.
+
+    ``route_args`` are the exact engine's settings for the whole board (width,
+    clearance, layers, shove, ...); the window runs them at ``resolution``.
+    ``margin`` is the first round's window margin in board units. No new
+    window starts once ``budget_s`` seconds have gone by (None: no limit),
+    and at most ``max_windows`` run per round."""
+    started = time.monotonic()
+    if rounds < 1 or not _open(result.failed):
+        return result
+    default_half = result.half_width
+    copper: dict[int, Copper] = {
+        net: (list(result.wires.get(net, [])), list(result.vias.get(net, [])))
+        for net in set(result.wires) | set(result.vias)
+    }
+    half = dict(result.net_half)
+    failed = list(result.failed)
+    base = build_board(dsn)
+    base_items = [(item, _item_box(item)) for item in base.get_items()]
+    layers = route_args.get("layers") or [
+        i for i, layer in enumerate(base.layer_structure.arr) if layer.is_signal
+    ]
+    labels = _pin_labels(base)
+    # the copper a window's routing can feel from outside it
+    context = 2 * (route_args["trace_width"] + route_args["clearance"]) + 2 * via_half + (
+        route_args.get("edge_clearance") or 0
+    )
+
+    def window_of(entry, reach: int) -> IntBox | None:
+        ends = [_end_point(labels, entry[0], label) for label in entry[1:3]]
+        ends = [p for p in ends if p is not None]
+        if not ends:
+            return None
+        return IntBox(
+            min(p.x for p in ends) - reach, min(p.y for p in ends) - reach,
+            max(p.x for p in ends) + reach, max(p.y for p in ends) + reach,
+        )
+
+    def area(box: IntBox | None) -> float:
+        return float("inf") if box is None else (box.ur.x - box.ll.x) * (box.ur.y - box.ll.y)
+
+    changed = out_of_time = False
+    for rnd in range(rounds):
+        reach = margin * (2 ** rnd)
+
+        # the cheap wins first: the smallest windows
+        todo = sorted(_open(list(failed)), key=lambda f: area(window_of(f, reach)))
+        for entry in todo[:max(int(max_windows), 1)]:
+            if budget_s is not None and time.monotonic() - started >= budget_s:
+                out_of_time = True
+                break
+            if entry not in failed:
+                continue  # an earlier window routed it
+            net = entry[0]
+            window = window_of(entry, reach)
+            if window is None:
+                continue
+            victims = {n for n, c in copper.items() if _inside(c, window)}
+            affected = victims | {net}
+            before = _open(f for f in failed if f[0] in affected)
+            keep = set(copper) - victims
+            view = IntBox(window.ll.x - context, window.ll.y - context,
+                          window.ur.x + context, window.ur.y + context)
+            board = _window_board(base, base_items, view, affected, copper, keep, half,
+                                  default_half, via_half, via_drill, layers, via_name)
+            sub = route_board_exact(
+                board, **route_args, resolution=resolution,
+                only_nets=frozenset(affected), bounds=window,
+                route_first=frozenset((f[0], f[1], f[2]) for f in before),
+            ).result
+            after = _open(f for f in sub.failed if f[0] in affected)
+            if len(after) >= len(before):
+                continue
+            # the window board left out what lies away from it, so copper
+            # reaching out of the window was never checked against it
+            if any(not _inside((sub.wires.get(n, []), sub.vias.get(n, [])), window)
+                   for n in affected if sub.wires.get(n) or sub.vias.get(n)):
+                continue
+            # a net keeping some of its copper is written at one width: the
+            # window's new copper has to have gone in at that width too
+            if any(
+                n not in victims and copper.get(n) and (sub.wires.get(n) or sub.vias.get(n))
+                and sub.net_half.get(n, default_half) != half.get(n, default_half)
+                for n in affected
+            ):
+                continue
+            for n in affected:
+                kept_wires, kept_vias = copper.get(n, ([], [])) if n not in victims else ([], [])
+                copper[n] = (kept_wires + sub.wires.get(n, []), kept_vias + sub.vias.get(n, []))
+                if n in victims:
+                    half.pop(n, None)
+                    if n in sub.net_half:
+                        half[n] = sub.net_half[n]
+            failed = [f for f in failed if f[0] not in affected] + [
+                f for f in sub.failed if f[0] in affected
+            ]
+            changed = True
+        if out_of_time or not _open(failed):
+            break
+
+    if not changed:
+        return result
+    out = RouteResult(default_half)
+    for net, (wires, vias) in copper.items():
+        for layer, path in wires:
+            out.add_wire(net, layer, path)
+        for location in dict.fromkeys(vias):
+            out.add_via(net, location)
+    out.failed = failed
+    out.unrouted = len(_open(failed))
+    out.net_half = half
+    out.narrowed = list(result.narrowed)
+    return out

src/freeroute/ses/model.py

@@ -57,6 +57,12 @@ class RoutingResult:
     """The complete routing output for a board, grouped by net."""
 
     nets: list[RoutedNet] = field(default_factory=list)
+    #: connections the router could not make: (net name, one end, other end,
+    #: the zone both ends sit in or "") -- a zone's fill may join the latter
+    unrouted: list[tuple[str, str, str, str]] = field(default_factory=list)
+    #: connections of a wider net class that only fitted at the default width
+    #: (net name, one end, other end); their net is written at the default
+    narrowed: list[tuple[str, str, str]] = field(default_factory=list)
 
     def net(self, name: str, *, create: bool = False) -> RoutedNet | None:
         """Return the :class:`RoutedNet` with ``name`` (creating it if asked)."""

tests/board/test_build.py

@@ -17,6 +17,7 @@ import pytest
 
 from freeroute.board import BasicBoard, ObstacleArea, Pin, build_board
 from freeroute.dsn import parse_dsn
+from freeroute.geometry import IntPoint
 
 sys.path.insert(0, str(Path(__file__).resolve().parent.parent))
 
@@ -62,11 +63,20 @@ def test_pin_count_matches_placement(dsn, board):
 
 
 def test_obstacle_count_matches_keepouts(dsn, board):
-    # each keepout expands to one obstacle per applicable layer; with no keepouts
-    # in this fixture the count is zero
-    assert len(board.get_obstacle_areas()) >= len(dsn.keepouts)
+    # Board-level keepouts plus every placed instance of a footprint-level one.
+    # This fixture has none of the first and six plated mounting holes, whose
+    # copper KiCad exports as a keepout on each layer.
+    images = {img.name: img for img in dsn.images}
+    placed = 0
+    for placement in dsn.placements:
+        image = images.get(placement.lib_name)
+        if image is None:
+            continue
+        per_part = len(image.keepouts) + len(image.via_keepouts) + len(image.wire_keepouts)
+        placed += per_part * sum(p.x is not None for p in placement.places)
     assert len(dsn.keepouts) == 0
-    assert board.get_obstacle_areas() == []
+    assert placed == 12
+    assert len(board.get_obstacle_areas()) == placed
 
 
 # --- per-item invariants ----------------------------------------------------
@@ -129,3 +139,152 @@ def test_board_net_set_covers_oracle_routed_nets(board):
     assert routed, "oracle produced no routed nets"
     # every net the reference router routed exists on our constructed board
     assert routed <= board.nets.names()
+
+
+# --- keepouts as KiCad exports them ------------------------------------------
+# Found on the TerraHawk charge-node boards (2026-09-27): a no-track ring along
+# the board edge arrives as one keyhole polygon, "keep router off" rule areas
+# arrive as wire_keepout, and neither may block the board's interior.
+
+_RING_DSN = """(pcb ring (parser) (resolution um 10) (unit um)
+  (structure
+    (layer F.Cu (type signal)) (layer B.Cu (type signal))
+    (boundary (path pcb 0  0 0  40000 0  40000 -30000  0 -30000  0 0))
+    (keepout "" (polygon F.Cu 0  0 0  40000 0  40000 -30000  0 -30000  0 0
+      500 -500  500 -29500  39500 -29500  39500 -500  500 -500  0 0))
+    (wire_keepout "pour" (polygon F.Cu 0  10000 -10000  20000 -10000  20000 -20000  10000 -20000))
+    (place_keepout "courtyard" (polygon F.Cu 0  30000 -10000  35000 -10000  35000 -20000  30000 -20000))
+    (rule (width 250) (clearance 150)))
+  (placement) (library) (network))"""
+
+
+def _areas(dsn_text):
+    return build_board(parse_dsn(dsn_text)).get_obstacle_areas()
+
+
+def _blocked(areas, x_um, y_um):
+    p = IntPoint(x_um * 10, y_um * 10)
+    return any(t.contains(p) for a in areas for t in a.tiles)
+
+
+def test_keyhole_ring_keepout_blocks_only_the_border():
+    areas = _areas(_RING_DSN)
+    assert _blocked(areas, 200, -15000)          # inside the 0.5 mm edge strip
+    assert not _blocked(areas, 5000, -5000)      # open board interior
+
+
+def test_wire_keepout_is_read_and_blocks_its_area():
+    dsn = parse_dsn(_RING_DSN)
+    assert [k.kind for k in dsn.keepouts].count("wire_keepout") == 1
+    assert _blocked(_areas(_RING_DSN), 15000, -15000)
+
+
+def test_place_keepout_does_not_block_routing():
+    assert not _blocked(_areas(_RING_DSN), 32500, -15000)
+
+
+def test_grid_router_leaves_the_interior_of_a_ring_keepout_open():
+    from freeroute.route.pipeline import route_dsn_board
+
+    ring_only = "\n".join(
+        line for line in _RING_DSN.splitlines() if "wire_keepout" not in line
+    ).replace(
+        "(placement) (library) (network)",
+        "(placement (component P (place P1 5000 -15000 front 0) (place P2 35000 -15000 front 0)))\n"
+        "  (library (image P (pin pad 1 0 0)) (padstack pad (shape (circle F.Cu 600)) (attach off)))\n"
+        "  (network (net N (pins P1-1 P2-1)))",
+    )
+    result, _, _ = route_dsn_board(parse_dsn(ring_only), max_passes=2)
+    assert result.routed_net_numbers
+
+
+# --- pads placed as KiCad places them (2026-09-27, TerraHawk rc4) ------------
+
+_PAD_DSN = """(pcb pads (parser) (resolution um 10) (unit um)
+  (structure
+    (layer F.Cu (type signal)) (layer B.Cu (type signal))
+    (boundary (path pcb 0  0 0  40000 0  40000 -30000  0 -30000  0 0))
+    (via "Via[0-1]_600:300_um")
+    (rule (width 250) (clearance 150)))
+  (placement
+    (component R (place TOP 10000 -10000 front 0) (place BOT 20000 -10000 back 0)
+                 (place ROT 30000 -10000 front 90)))
+  (library
+    (image R (pin rect 1 -1000 0))
+    (padstack rect (shape (rect F.Cu -400 -250 400 250)) (attach off))
+    (padstack "Via[0-1]_600:300_um" (shape (circle F.Cu 600)) (shape (circle B.Cu 600)) (attach off)))
+  (network))"""
+
+
+def _pins_by_ref(text):
+    board = build_board(parse_dsn(text))
+    return {p.component_ref: p for p in board.get_pins()}, board
+
+
+def test_back_side_pad_moves_to_the_bottom_layer():
+    pins, board = _pins_by_ref(_PAD_DSN)
+    names = [layer.name for layer in board.layer_structure.arr]
+    assert [names[i] for i in pins["TOP"].layers] == ["F.Cu"]
+    assert [names[i] for i in pins["BOT"].layers] == ["B.Cu"]
+
+
+def test_back_side_pin_offset_is_mirrored():
+    pins, _ = _pins_by_ref(_PAD_DSN)
+    assert pins["TOP"].location.x == (10000 - 1000) * 10
+    assert pins["BOT"].location.x == (20000 + 1000) * 10
+
+
+def test_rotated_part_rotates_its_pad_outline():
+    pins, _ = _pins_by_ref(_PAD_DSN)
+    flat = pins["TOP"].shape.bounding_box()
+    turned = pins["ROT"].shape.bounding_box()
+    assert (flat.ur.x - flat.ll.x, flat.ur.y - flat.ll.y) == (8000, 5000)
+    assert (turned.ur.x - turned.ll.x, turned.ur.y - turned.ll.y) == (5000, 8000)
+
+
+def test_oval_pad_keeps_its_width():
+    oval = _PAD_DSN.replace("(shape (rect F.Cu -400 -250 400 250))", "(shape (path F.Cu 500  -300 0  300 0))")
+    pins, _ = _pins_by_ref(oval)
+    box = pins["TOP"].shape.bounding_box()
+    assert box.ur.y - box.ll.y == 5000       # the aperture, not a zero-height line
+    assert box.ur.x - box.ll.x == 11000      # centreline 600 um plus the aperture
+
+
+def test_via_size_comes_from_the_via_padstack():
+    from freeroute.route.pipeline import _via_half_board
+
+    assert _via_half_board(parse_dsn(_PAD_DSN), 10) == 3000   # 0.6 mm via, board units
+
+
+# --- rule areas: overlap only ------------------------------------------------
+
+_CHANNEL_DSN = """(pcb channel.dsn
+  (parser (string_quote ")) (resolution um 10) (unit um)
+  (structure
+    (layer F.Cu (type signal)) (layer B.Cu (type signal))
+    (boundary (path pcb 0  0 0  40000 0  40000 -30000  0 -30000  0 0))
+    (keepout "{name}top" (polygon signal 0  18000 0  22000 0  22000 -14750  18000 -14750))
+    (keepout "{name}bottom" (polygon signal 0  18000 -15250  22000 -15250  22000 -30000  18000 -30000))
+    (rule (width 250) (clearance 150)))
+  (placement (component P (place P1 5000 -15000 front 0) (place P2 35000 -15000 front 0)))
+  (library (image P (pin pad 1 0 0)) (padstack pad (shape (circle F.Cu 600)) (attach off)))
+  (network (net N (pins P1-1 P2-1))))"""
+
+
+def test_a_keepout_named_rule_area_takes_no_clearance():
+    named = _areas(_CHANNEL_DSN.format(name="rule_area_"))
+    plain = _areas(_CHANNEL_DSN.format(name=""))
+    assert named and not any(a.clearance for a in named)
+    assert plain and all(a.clearance for a in plain)
+
+
+def _route_channel(name):
+    from freeroute.route.pipeline import build_exact_routing_result
+
+    return build_exact_routing_result(parse_dsn(_CHANNEL_DSN.format(name=name)), resolution=2)
+
+
+def test_a_trace_may_run_beside_a_rule_area_closer_than_clearance():
+    # the 0.5 mm channel fits a 0.25 mm trace, but not with 0.15 mm each side
+    assert _route_channel("rule_area_").unrouted == []
+    assert _route_channel("").unrouted != []

tests/board/test_search_tree.py

@@ -62,3 +62,37 @@ def test_has_violation_ignores_static_pad_pairs():
     # a routed trace of net 3 within clearance of pad net 1 -> violation
     tree.insert(shape(2, 3, 0, IntBox(11, 0, 20, 10), routed=True))
     assert tree.has_violation(clearance=20) is not None
+
+
+def test_a_rule_area_conflicts_only_on_overlap():
+    tree = ShapeSearchTree()
+    tree.insert(TreeShape(1, -1, frozenset({0}), IntBox(100, 0, 200, 100), clearance=False))
+    near = IntBox(0, 0, 95, 100)  # 5 short of the area, well inside clearance 50
+    over = IntBox(0, 0, 105, 100)
+    assert not tree.clearance_conflict(near, 7, 0, 50)
+    assert tree.clearance_conflict(over, 7, 0, 50)
+
+
+def test_an_ordinary_keepout_still_needs_clearance():
+    tree = ShapeSearchTree()
+    tree.insert(TreeShape(1, -1, frozenset({0}), IntBox(100, 0, 200, 100)))
+    assert tree.clearance_conflict(IntBox(0, 0, 95, 100), 7, 0, 50)
+
+
+def test_the_routed_board_check_treats_a_rule_area_the_same_way():
+    tree = ShapeSearchTree()
+    tree.insert(TreeShape(1, -1, frozenset({0}), IntBox(100, 0, 200, 100), clearance=False))
+    tree.insert(TreeShape(2, 7, frozenset({0}), IntBox(0, 0, 95, 100), routed=True))
+    assert tree.has_violation(50) is None
+    tree.insert(TreeShape(3, 7, frozenset({0}), IntBox(150, 0, 160, 100), routed=True))
+    assert tree.has_violation(50) is not None
+
+
+
+def test_rule_area_overlap_sees_only_rule_areas():
+    tree = ShapeSearchTree()
+    tree.insert(TreeShape(1, -1, frozenset({0}), IntBox(100, 0, 200, 100), clearance=False))
+    tree.insert(TreeShape(2, -1, frozenset({0}), IntBox(300, 0, 400, 100)))
+    assert tree.rule_area_overlap(IntBox(90, 40, 110, 60), 0)
+    assert not tree.rule_area_overlap(IntBox(290, 40, 310, 60), 0)
+    assert not tree.rule_area_overlap(IntBox(90, 40, 110, 60), 1)

tests/dsn/test_reader.py

@@ -156,3 +156,26 @@ def test_unplaced_component_has_no_coords():
     place = board.placements[0].places[0]
     assert place.name == "U9"
     assert place.x is None and place.y is None
+
+
+# --- string_quote ----------------------------------------------------------
+
+_QUOTED = """(pcb q.dsn
+  (parser (string_quote {q}) (space_in_quoted_tokens on))
+  (resolution um 10) (unit um)
+  (structure (layer F.Cu (type signal)) (boundary (path pcb 0 0 0 1000 0 1000 1000 0 1000 0 0)))
+  (placement (component "SW1" (place SW1 100 100 front 0 (PN {pn}))))
+  (library)
+  (network)
+)"""
+
+
+def test_a_bare_apostrophe_is_an_atom_when_the_file_quotes_with_double_quotes():
+    # KiCad declares " and writes a keycap's part number as a bare '
+    board = parse_dsn(_QUOTED.format(q='"', pn="'"))
+    assert board.parser.string_quote == '"'
+
+
+def test_the_declared_quote_character_is_the_one_that_opens_strings():
+    board = parse_dsn(_QUOTED.format(q="'", pn="'10k 1%'").replace('"SW1"', "'SW1'"))
+    assert board.parser.string_quote == "'"

tests/oracle.py

@@ -111,12 +111,17 @@ def route_dsn(dsn_path: str | Path, *, max_passes: int = 6, timeout: int = 180)
     with tempfile.NamedTemporaryFile(suffix=".ses", delete=False) as tmp:
         out_path = tmp.name
     try:
+        # Headless: without these the JAR opens its GUI on the developer's
+        # desktop for every oracle run.
+        env = {k: v for k, v in os.environ.items() if k not in ("DISPLAY", "WAYLAND_DISPLAY")}
         subprocess.run(
-            [JAVA, "-jar", JAR, "-de", str(dsn_path), "-do", out_path, "-mp", str(max_passes)],
+            [JAVA, "-Djava.awt.headless=true", "-jar", JAR, "-de", str(dsn_path),
+             "-do", out_path, "-mp", str(max_passes), "--gui.enabled=false"],
             capture_output=True,
             text=True,
             timeout=timeout,
             check=False,
+            env=env,
         )
         text = Path(out_path).read_text()
     finally:

tests/route/test_axis_escapes.py

@@ -0,0 +1,113 @@
+"""Pins of a fine-pitch part turned off the grid axes leave along their pads.
+
+A QFN at 45 degrees has no straight exit: every horizontal or vertical step
+from a pin passes its neighbours closer than the clearance (0.35 mm away on
+each axis at 0.5 mm pitch). The grid leaves along the pad's own axis first,
+past the pin row, and the exact engine checks that slanted leg on its exact
+copper. Found on th-eda's lift ESC, where a QFN-24 at 45 degrees left 15
+connections unroutable on an empty board.
+"""
+
+from __future__ import annotations
+
+import math
+
+import pytest
+
+from freeroute.board import build_board
+from freeroute.dsn import parse_dsn
+from freeroute.geometry import IntPoint, overlaps_2d, segment_slab
+from freeroute.route.grid_router import GridRouter
+from freeroute.route.pipeline import (
+    _rule_clearance_dsn,
+    _rule_width_dsn,
+    _via_half_board,
+    build_exact_routing_result,
+)
+
+
+def _qfn_side_dsn(rotation: float) -> str:
+    """Two rows of five 0.25 x 0.8 mm pads at 0.5 mm pitch (one side of a
+    QFN and its opposite side), turned by ``rotation``; each pin of the top
+    row is its own net, routed to a pad 4.5 mm out, the pads fanned 1.5 mm
+    apart."""
+    cx, cy = 100000, -100000
+    t = math.radians(rotation)
+    out = (-math.sin(t), math.cos(t))  # the pads' outward axis after turning
+    along = (math.cos(t), math.sin(t))  # the pin row
+    pins, targets, nets = [], [], []
+    for i in range(5):
+        x = -1000 + 500 * i
+        pins += [f"(pin P {i + 1} {x} 1000)", f"(pin P {i + 6} {x} -1000)"]
+        px = cx + x * math.cos(t) - 1000 * math.sin(t)
+        py = cy + x * math.sin(t) + 1000 * math.cos(t)
+        spread = 1500 * (i - 2) - x  # fan the far pads out to 1.5 mm apart
+        tx = px + 4500 * out[0] + spread * along[0]
+        ty = py + 4500 * out[1] + spread * along[1]
+        targets.append(f"(place T{i + 1} {round(tx)} {round(ty)} front 0)")
+        nets.append(f"(net N{i} (pins U1-{i + 1} T{i + 1}-1))")
+    return f"""(pcb qfn (parser) (resolution um 10) (unit um)
+  (structure
+    (layer F.Cu (type signal)) (layer B.Cu (type signal))
+    (boundary (path pcb 0  115000 -115000  85000 -115000  85000 -85000  115000 -85000
+      115000 -115000))
+    (via "Via[0-1]_450:200_um")
+    (rule (width 150) (clearance 150)))
+  (placement
+    (component Q (place U1 {cx} {cy} front {rotation}))
+    (component T {" ".join(targets)}))
+  (library
+    (image Q {" ".join(pins)})
+    (image T (pin t 1 0 0))
+    (padstack P (shape (rect F.Cu -125 -400 125 400)) (attach off))
+    (padstack t (shape (rect F.Cu -300 -300 300 300)) (attach off))
+    (padstack "Via[0-1]_450:200_um" (shape (circle F.Cu 450)) (shape (circle B.Cu 450))
+      (attach off)))
+  (network {" ".join(nets)}))"""
+
+
+@pytest.mark.parametrize("rotation", [45, 30, -45])
+def test_a_turned_fine_pitch_part_gets_its_pins_out(rotation):
+    result = build_exact_routing_result(parse_dsn(_qfn_side_dsn(rotation)), resolution=2, shove=True)
+    assert result.unrouted == []
+
+
+def test_the_exit_runs_along_the_pad_axis_and_clears_the_neighbours():
+    dsn = parse_dsn(_qfn_side_dsn(45))
+    s = dsn.resolution.value
+    board = build_board(dsn)
+    router = GridRouter(
+        board,
+        trace_width=round(_rule_width_dsn(dsn) * s),
+        clearance=round(_rule_clearance_dsn(dsn) * s),
+        via_half=_via_half_board(dsn, s),
+        orthogonal=True,
+    )
+    pins = {p.name: p for p in board.get_pins() if p.component_ref == "U1"}
+    pin = pins["3"]
+    exit_point = router._axis_exit(pin)
+    assert exit_point is not None
+    dx, dy = exit_point.x - pin.location.x, exit_point.y - pin.location.y
+    assert abs(abs(dx) - abs(dy)) <= 2  # along the 45-degree axis
+    leg = segment_slab(pin.location, exit_point, router.half_width + router.clearance)
+    for name in ("2", "4"):
+        assert not overlaps_2d(leg, pins[name].shape)
+
+
+def test_a_pad_on_the_grid_axes_keeps_the_usual_exits():
+    dsn = parse_dsn(_qfn_side_dsn(0))
+    s = dsn.resolution.value
+    board = build_board(dsn)
+    router = GridRouter(board, trace_width=round(_rule_width_dsn(dsn) * s),
+                        clearance=round(_rule_clearance_dsn(dsn) * s), via_half=_via_half_board(dsn, s))
+    pin = next(p for p in board.get_pins() if p.component_ref == "U1" and p.name == "3")
+    assert router._axis_exit(pin) is None
+
+
+def test_a_slanted_slab_is_tight_where_a_bounding_box_is_not():
+    slab = segment_slab(IntPoint(0, 0), IntPoint(10000, 10000), 750)
+    # a point beside the diagonal but inside its bounding box
+    from freeroute.geometry import IntBox
+
+    assert not overlaps_2d(slab, IntBox(8000, 0, 8100, 100))
+    assert overlaps_2d(slab, IntBox(4900, 4900, 5100, 5100))

tests/route/test_fixed_wiring.py

@@ -0,0 +1,108 @@
+"""Tracks and vias already on the board (the DSN's wiring) are fixed copper."""
+
+from __future__ import annotations
+
+from freeroute.board import build_board
+from freeroute.dsn import parse_dsn
+from freeroute.route.pipeline import route_dsn_board_exact
+
+_DSN = """(pcb wired (parser) (resolution um 10) (unit um)
+  (structure
+    (layer F.Cu (type signal)) (layer B.Cu (type signal))
+    (boundary (path pcb 0  0 0  30000 0  30000 -20000  0 -20000  0 0))
+    (via "Via[0-1]_600:300_um") (rule (width 250) (clearance 200)))
+  (placement (component S (place A1 5000 -10000 front 0) (place A2 25000 -10000 front 0)))
+  (library
+    (image S (pin smd 1 0 0))
+    (padstack smd (shape (rect F.Cu -400 -400 400 400)) (attach off))
+    (padstack "Via[0-1]_600:300_um" (shape (circle F.Cu 600)) (shape (circle B.Cu 600)) (attach off)))
+  (network (net SIG (pins A1-1 A2-1)) (net GND))
+  (wiring
+    (wire (path F.Cu 400  15000 0  15000 -20000) (net GND) (type route))
+    (via "Via[0-1]_600:300_um"  8000 -14000 (net GND) (type route))))"""
+
+
+def test_wiring_is_read_with_its_nets():
+    dsn = parse_dsn(_DSN)
+    assert [(w.net, w.layer, w.width) for w in dsn.wires] == [("GND", "F.Cu", 400.0)]
+    assert [(v.net, v.x, v.y) for v in dsn.vias] == [("GND", 8000.0, -14000.0)]
+
+
+def test_wiring_is_fixed_copper_and_not_a_connection_to_route():
+    board = build_board(parse_dsn(_DSN))
+    copper = board.get_fixed_copper()
+    gnd = next(n.net_number for n in board.nets if n.name == "GND")
+    assert copper and all(net == gnd for net, _, _ in copper)
+    assert not any(gnd in p.net_nos for p in board.get_pins())
+
+
+def test_other_nets_route_around_a_fixed_track():
+    dsn = parse_dsn(_DSN)
+    exact, scale, names = route_dsn_board_exact(dsn, resolution=2)
+    sig = next(i + 1 for i, n in enumerate(dsn.nets) if n.name == "SIG")
+    assert sig in exact.result.routed_net_numbers
+    assert exact.drc_clean
+    wall = 15000 * scale
+    for layer, pts in exact.result.wires.get(sig, []):
+        if names[layer] != "F.Cu":
+            continue
+        for p, q in zip(pts, pts[1:], strict=False):
+            assert not (min(p.x, q.x) < wall < max(p.x, q.x)), "crossed the GND track on F.Cu"
+
+
+# --- fixed wiring as connectivity ------------------------------------------
+
+_FANOUT = """(pcb fanout (parser) (resolution um 10) (unit um)
+  (structure
+    (layer F.Cu (type signal)) (layer In1.Cu (type power)) (layer In2.Cu (type power))
+    (layer B.Cu (type signal))
+    (boundary (path pcb 0  0 0  30000 0  30000 -20000  0 -20000  0 0))
+    (plane GND (polygon In1.Cu 0  500 -500  29500 -500  29500 -19500  500 -19500  500 -500))
+    (via "Via[0-3]_600:300_um") (rule (width 150) (clearance 150)))
+  (placement (component S (place G1 5000 -10000 front 0) (place A 10000 -10000 front 0)
+                          (place B 25000 -11500 back 0)))
+  (library
+    (image S (pin smd 1 0 0))
+    (padstack smd (shape (rect F.Cu -300 -300 300 300)) (attach off))
+    (padstack "Via[0-3]_600:300_um" (shape (circle F.Cu 600)) (shape (circle B.Cu 600)) (attach off)))
+  (network (net GND (pins G1-1)) (net SIG (pins A-1 B-1)))
+  (wiring
+    (wire (path F.Cu 150  5000 -10000  5000 -11500) (net GND) (type route))
+    (via "Via[0-3]_600:300_um"  5000 -11500 (net GND) (type route))
+    (wire (path F.Cu 150  10000 -10000  10000 -11500) (net SIG) (type route))
+    (via "Via[0-3]_600:300_um"  10000 -11500 (net SIG) (type route))
+    (wire (path F.Cu 300  2000 -2000  8000 -2000) (net GND) (type route))))"""
+
+
+def test_a_pad_fanned_out_to_its_plane_needs_no_route():
+    dsn = parse_dsn(_FANOUT)
+    exact, _scale, _names = route_dsn_board_exact(dsn, resolution=2)
+    gnd = next(i + 1 for i, n in enumerate(dsn.nets) if n.name == "GND")
+    assert exact.result.failed == []
+    assert not exact.result.vias.get(gnd) and not exact.result.wires.get(gnd)
+
+
+def test_a_fanned_out_signal_is_routed_from_its_via():
+    # B is on the bottom face, level with A's fan-out via: starting from that
+    # via on B.Cu is the cheapest way, and needs no via of its own
+    dsn = parse_dsn(_FANOUT)
+    exact, scale, names = route_dsn_board_exact(dsn, resolution=2)
+    sig = next(i + 1 for i, n in enumerate(dsn.nets) if n.name == "SIG")
+    assert sig in exact.result.routed_net_numbers
+    assert not exact.result.vias.get(sig), "the fan-out via is already there"
+    assert {names[layer] for layer, _ in exact.result.wires[sig]} == {"B.Cu"}
+
+
+def test_the_session_never_repeats_copper_already_on_the_board():
+    # the JAR writes the DSN's wiring back into its session, and an applier
+    # then adds it a second time on top of itself; freeroute writes only
+    # what it routed
+    from freeroute.route.pipeline import build_exact_routing_result
+
+    fixed_vias = {(5000.0, -11500.0), (10000.0, -11500.0)}
+    fixed_paths = {(5000.0, -10000.0, 5000.0, -11500.0), (10000.0, -10000.0, 10000.0, -11500.0),
+                   (2000.0, -2000.0, 8000.0, -2000.0)}
+    result = build_exact_routing_result(parse_dsn(_FANOUT), resolution=2)
+    for net in result.nets:
+        assert not {(v.x, v.y) for v in net.vias} & fixed_vias
+        assert not {tuple(w.coords) for w in net.wires} & fixed_paths

tests/route/test_grid_exact_agreement.py

@@ -0,0 +1,284 @@
+"""The grid must not believe copper legal that the exact check then refuses.
+
+Each case is one way the two used to disagree on roomba-ESP12E: a rotated oval
+pad modelled as an inflated box (and opened to its own net), a via shared by
+two connections of a net losing its footprint when one of them is ripped, and
+a wider net class searched as if it were the default width.
+"""
+
+from __future__ import annotations
+
+import math
+
+import pytest
+
+from freeroute.board import build_board
+from freeroute.dsn import parse_dsn
+from freeroute.geometry import IntBox, Simplex
+from freeroute.route.grid_router import GridRouter
+from freeroute.route.pipeline import (
+    _rule_clearance_dsn,
+    _rule_width_dsn,
+    _via_half_board,
+    build_exact_routing_result,
+)
+
+# --- rotated oval pads -------------------------------------------------------
+
+
+def _socket_dsn(rotation: float, layout: str) -> str:
+    """A 1x4 2.54 mm socket strip (rect pin 1, oval pins 2-4) at ``rotation``,
+    each pin its own net, routed to a small SMD pad 0.9 mm away."""
+    cx, cy = 100000, -100000
+    t = math.radians(rotation)
+    ax = (math.cos(t), math.sin(t))
+    perp = (-math.sin(t), math.cos(t))
+    places = []
+    for i in range(4):
+        px, py = cx + 2540 * i * ax[0], cy + 2540 * i * ax[1]
+        side = 1 if i % 2 == 0 else -1
+        if layout == "y":
+            tx, ty = px, py + side * 9000
+        else:
+            tx, ty = px + side * 8000 * perp[0], py + side * 8000 * perp[1]
+        places.append(f"(place T{i + 1} {round(tx)} {round(ty)} front 0)")
+    nets = " ".join(f"(net N{i} (pins P3-{i + 1} T{i + 1}-1))" for i in range(4))
+    return f"""(pcb socket (parser) (resolution um 10) (unit um)
+  (structure
+    (layer F.Cu (type signal)) (layer B.Cu (type signal))
+    (boundary (path pcb 0  125000 -115000  85000 -115000  85000 -75000  125000 -75000
+      125000 -115000))
+    (via "Via[0-1]_800:400_um")
+    (rule (width 300) (clearance 250)))
+  (placement
+    (component S (place P3 {cx} {cy} front {rotation}))
+    (component T {" ".join(places)}))
+  (library
+    (image S (pin R 1 0 0) (pin O 2 2540 0) (pin O 3 5080 0) (pin O 4 7620 0))
+    (image T (pin t 1 0 0))
+    (padstack O (shape (path F.Cu 1727.2 0 -152.4 0 152.4))
+      (shape (path B.Cu 1727.2 0 -152.4 0 152.4)) (attach off))
+    (padstack R (shape (rect F.Cu -863.6 -1016 863.6 1016))
+      (shape (rect B.Cu -863.6 -1016 863.6 1016)) (attach off))
+    (padstack t (shape (rect F.Cu -500 -500 500 500)) (attach off))
+    (padstack "Via[0-1]_800:400_um" (shape (circle F.Cu 800)) (shape (circle B.Cu 800))
+      (attach off)))
+  (network {nets}
+    (class c N0 N1 N2 N3 (circuit (use_via "Via[0-1]_800:400_um"))
+      (rule (width 300) (clearance 250)))))"""
+
+
+def test_a_rotated_oval_pad_is_its_outline_not_its_bounding_box():
+    board = build_board(parse_dsn(_socket_dsn(60, "y")))
+    oval = next(p for p in board.get_pins() if p.component_ref == "P3" and p.name == "2")
+    assert isinstance(oval.shape, Simplex) and not oval.shape.is_int_box()
+    box = oval.shape.bounding_box()
+    assert oval.shape.contains(oval.location)
+    assert not oval.shape.contains(box.ll) and not oval.shape.contains(box.ur)
+
+
+@pytest.mark.parametrize("layout", ["y", "perp"])
+def test_routes_leaving_a_rotated_socket_pass_the_exact_check(layout):
+    result = build_exact_routing_result(
+        parse_dsn(_socket_dsn(60, layout)), resolution=2, shove=True
+    )
+    assert result.unrouted == []
+
+
+# --- a via two connections share --------------------------------------------
+
+_SHARED_VIA = """(pcb shared (parser) (resolution um 10) (unit um)
+  (structure
+    (layer Top (type signal)) (layer Bottom (type signal))
+    (boundary (path pcb 0  0 0  20000 0  20000 -20000  0 -20000  0 0))
+    (via "Via[0-1]_800:400_um")
+    (rule (width 300) (clearance 250)))
+  (library
+    (padstack p (shape (rect Top -400 -400 400 400)) (attach off))
+    (padstack "Via[0-1]_800:400_um" (shape (circle Top 800)) (shape (circle Bottom 800))
+      (attach off))
+    (image PAD (pin p 1 0 0)))
+  (placement (component PAD
+    (place G1 3000 -5000 front 0) (place G2 3000 -15000 front 0)
+    (place G3 17000 -10000 front 0) (place S1 3000 -10000 front 0)
+    (place S2 17000 -3000 front 0)))
+  (network (net GND (pins G1-1 G2-1 G3-1)) (net SIG (pins S1-1 S2-1))))"""
+
+
+def _line(a, b, layer):
+    (x, y), (x1, y1) = a, b
+    out = [(x, y, layer)]
+    while x != x1:
+        x += 1 if x1 > x else -1
+        out.append((x, y, layer))
+    while y != y1:
+        y += 1 if y1 > y else -1
+        out.append((x, y, layer))
+    return out
+
+
+def test_a_shared_via_keeps_its_footprint_when_one_user_is_ripped():
+    dsn = parse_dsn(_SHARED_VIA)
+    s = dsn.resolution.value
+    router = GridRouter(
+        build_board(dsn),
+        trace_width=round(_rule_width_dsn(dsn) * s),
+        clearance=round(_rule_clearance_dsn(dsn) * s),
+        via_half=_via_half_board(dsn, s),
+    )
+    conns = router._conns = router._build_connections()
+    gnd = [c for c in conns if len({c.a.component_ref, c.b.component_ref} & {"G1", "G2", "G3"})]
+    sig = next(c for c in conns if c not in gnd)
+    first, second = gnd
+    g3 = router._cell_of(next(p for p in router.board.get_pins() if p.component_ref == "G3").location)
+    via = (g3[0] - 10, g3[1])
+
+    def through_via(conn):
+        a, b = router._cell_of(conn.a.location), router._cell_of(conn.b.location)
+        return _line(a, via, 0) + _line(via, b, 1)
+
+    router._commit(first, through_via(first))
+    router._commit(second, through_via(second))
+    footprint = [c for c in router._via_cells(via) if c != via]
+    router._rip(first)
+
+    assert second.routed and via in second.via_cells
+    assert all(router._via_claims.get(c) == [second.index] for c in footprint)
+    # another net still keeps its distance from the via that is left
+    assert all(router._enter_cost_base(c, 0, sig.net_no, False, conns) is None for c in footprint)
+
+
+def test_a_route_through_a_shared_via_rips_every_user():
+    """Two connections of a net share a via. Another net routed through it
+    in rip-up mode has to rip both, or the one left keeps its via under the
+    new trace and the exact check throws one of them out."""
+    dsn = parse_dsn(_SHARED_VIA)
+    s = dsn.resolution.value
+    router = GridRouter(
+        build_board(dsn),
+        trace_width=round(_rule_width_dsn(dsn) * s),
+        clearance=round(_rule_clearance_dsn(dsn) * s),
+        via_half=_via_half_board(dsn, s),
+    )
+    conns = router._conns = router._build_connections()
+    gnd = [c for c in conns if len({c.a.component_ref, c.b.component_ref} & {"G1", "G2", "G3"})]
+    sig = next(c for c in conns if c not in gnd)
+    first, second = gnd
+    g3 = router._cell_of(next(p for p in router.board.get_pins() if p.component_ref == "G3").location)
+    via = (g3[0] - 10, g3[1])
+
+    def through_via(conn):
+        a, b = router._cell_of(conn.a.location), router._cell_of(conn.b.location)
+        return _line(a, via, 0) + _line(via, b, 1)
+
+    router._commit(first, through_via(first))
+    router._commit(second, through_via(second))
+    # the via's copper alone: footprint cells no trace or trace halo covers
+    crossing = [
+        node
+        for c in router._via_cells(via)
+        for node in ((*c, 0), (*c, 1))
+        if node not in router._cell_owner and node not in router._halo
+    ]
+    assert crossing
+
+    assert router._crossed_owners(crossing, sig.net_no, conns) == {first.index, second.index}
+
+
+# --- a wider net class --------------------------------------------------------
+
+_WIDE = """(pcb wide (parser) (resolution um 10) (unit um)
+  (structure
+    (layer F.Cu (type signal))
+    (boundary (path pcb 0  0 0  20000 0  20000 -10000  0 -10000  0 0))
+    (rule (width 300) (clearance 250)))
+  (placement (component S (place P1 2000 -5000 front 0) (place P2 18000 -5000 front 0)
+     (place Q1 10000 {ylo} front 0) (place Q2 10000 {yhi} front 0)
+     (place Q3 10000 -1000 front 0) (place Q4 10000 -9000 front 0)))
+  (library (image S (pin pad 1 0 0)) (padstack pad (shape (rect F.Cu -600 -600 600 600)) (attach off)))
+  (network (net PWR (pins P1-1 P2-1)) (net SIG (pins Q1-1 Q3-1)) (net SIG2 (pins Q2-1 Q4-1))
+    (class Power PWR (rule (width 500) (clearance 250)))))"""
+
+
+@pytest.mark.parametrize("resolution", [1, 2])
+@pytest.mark.parametrize("gap", [900, 1000, 1075])
+def test_a_wide_net_past_pads_it_does_not_fit_between_is_not_refused(gap, resolution):
+    # 0.3 mm fits the gap between the two pads, 0.5 mm does not: the grid
+    # must see that, rather than lay it wide and have the exact check drop it
+    ylo, yhi = -5000 - gap // 2 - 600, -5000 + gap // 2 + 600
+    result = build_exact_routing_result(
+        parse_dsn(_WIDE.format(ylo=ylo, yhi=yhi)), resolution=resolution
+    )
+    assert result.unrouted == []
+
+
+def _wide_router():
+    dsn = parse_dsn(_WIDE.format(ylo=-6050, yhi=-3950))
+    s = dsn.resolution.value
+    pwr = next(i for i, net in enumerate(dsn.nets, 1) if net.name == "PWR")
+    return GridRouter(
+        build_board(dsn),
+        trace_width=round(_rule_width_dsn(dsn) * s),
+        clearance=round(_rule_clearance_dsn(dsn) * s),
+        resolution=2,
+        net_widths={pwr: 5000},
+    ), pwr
+
+
+def test_a_wide_trace_keeps_clear_of_a_default_one_at_the_grid_diagonal():
+    router, _pwr = _wide_router()
+    # 0.5 mm against 0.3 mm needs 0.25 + 0.25 + 0.15 = 0.65 mm between centres,
+    # on either axis, since the exact check compares boxes
+    need = 2500 + router.clearance + router.half_width
+    for dx, dy in [(2, 2), (2, 1), (1, 2)]:
+        assert max(dx, dy) * router.step < need
+        assert (dx, dy) in router._halo_for(2500)
+
+
+def test_a_wide_rip_up_route_counts_what_its_extra_width_crosses():
+    router, pwr_net = _wide_router()
+    conns = router._conns = router._build_connections()
+    pwr = next(c for c in conns if c.net_no == pwr_net)
+    other = next(c for c in conns if c.net_no != pwr_net)
+    # a default-width trace two cells from the wide route's path
+    x, y = 20, 5
+    router._commit(other, _line((x - 3, y + 2), (x + 3, y + 2), 0))
+    path = _line((x - 3, y), (x + 3, y), 0)
+    spread = router._spread_for(2500)
+    assert other.index not in router._crossed_owners(path, pwr.net_no, conns)
+    assert other.index in router._crossed_owners(path, pwr.net_no, conns, spread)
+
+
+def test_a_pad_cell_check_uses_the_rotated_outline():
+    board = build_board(parse_dsn(_socket_dsn(60, "y")))
+    router = GridRouter(board, trace_width=3000, clearance=2500, resolution=2)
+    oval = next(p for p in board.get_pins() if p.component_ref == "P3" and p.name == "2")
+    box = oval.shape.bounding_box()
+    margin = router.clearance + router.half_width
+    exact = set(router._pad_cells(oval.shape, box, margin))
+    boxed = set(router._cells_in_box(box, margin))
+    assert exact < boxed
+    for cell in boxed - exact:
+        c = router._cell_center(cell)
+        square = IntBox(c.x - margin, c.y - margin, c.x + margin, c.y + margin)
+        assert oval.shape.intersection(square).dimension() != 2
+
+
+def test_a_via_by_a_chamfered_corner_is_judged_round():
+    """The grid keeps a via's centre its radius plus the edge clearance from
+    the outline. The exact check used the via's square, whose corner reaches
+    past a 45-degree chamfer where the round via does not."""
+    from freeroute.board.outline import BoardOutline
+    from freeroute.geometry import IntBox, IntPoint
+    from freeroute.route.exact_router import _inside_outline
+
+    # a 10 mm square with its lower-left corner cut at 45 degrees
+    outline = BoardOutline([IntPoint(*p) for p in
+                            [(30, 0), (100, 0), (100, 100), (0, 100), (0, 30)]])
+    half, edge = 4, 1
+    via = IntPoint(19, 20)  # its centre 6.4 from the chamfer x + y = 30
+    square = IntBox(via.x - half, via.y - half, via.x + half, via.y + half)
+    assert not outline.box_clear(square, edge)  # the square's corner: 0.7 away
+    assert _inside_outline(outline, [], [via], half + edge, edge)
+    # 4.2 from the chamfer: the round via itself is too close
+    assert not _inside_outline(outline, [], [IntPoint(18, 18)], half + edge, edge)

tests/route/test_negotiate.py

@@ -0,0 +1,65 @@
+"""--negotiate: PathFinder-style rounds on the empty board before routing."""
+
+from __future__ import annotations
+
+from pathlib import Path
+
+import pytest
+
+from freeroute.board import build_board
+from freeroute.dsn import parse_dsn
+from freeroute.route.grid_router import GridRouter
+from freeroute.route.pipeline import _rule_clearance_dsn, _rule_width_dsn, route_dsn_board
+
+FIXTURES = Path(__file__).resolve().parent.parent / "dsn" / "fixtures"
+
+
+def _router(name, negotiate):
+    dsn = parse_dsn((FIXTURES / name).read_text())
+    s = dsn.resolution.value
+    return GridRouter(
+        build_board(dsn),
+        trace_width=round(_rule_width_dsn(dsn) * s),
+        clearance=round(_rule_clearance_dsn(dsn) * s),
+        negotiate=negotiate,
+    )
+
+
+def test_negotiation_leaves_the_board_empty_and_the_ends_as_they_were():
+    router = _router("true_density.dsn", 3)
+    conns = router._conns = router._build_connections()
+    ends = [(c.a_end, c.b_end) for c in conns]
+    router._negotiate(list(conns), conns)
+    assert router._history  # a dense board has contested cells
+    assert not router._cell_owner and not router._halo and not router._via_claims
+    assert not any(c.routed for c in conns)
+    assert [(c.a_end, c.b_end) for c in conns] == ends
+    assert router._present is None
+
+
+def test_sharing_is_priced_only_for_other_nets():
+    router = _router("true_density.dsn", 1)
+    node = (3, 4, 0)
+    router._history[node] = 2.0
+    router._present, router._present_cost = {node: {7: 1, 9: 2}}, 0.5
+    assert router._congestion(node, 7) == pytest.approx(2.5)  # one other net
+    assert router._congestion(node, 5) == pytest.approx(3.0)  # two other nets
+    router._present = None
+    assert router._congestion(node, 5) == pytest.approx(2.0)  # history only, after
+
+
+@pytest.mark.parametrize("name", ["ripup_needed.dsn", "true_density.dsn", "kicad_routable.dsn"])
+def test_negotiated_routing_keeps_the_occupancy_honest(name):
+    """Only routed connections hold cells afterwards, as without negotiation."""
+    router = _router(name, 3)
+    router.route()
+    conns = router._conns
+    assert all(conns[i].routed for i in router._cell_owner.values())
+    assert all(conns[i].routed for claims in router._halo.values() for i in claims)
+
+
+def test_option_reaches_the_router_and_is_off_by_default():
+    text = (FIXTURES / "kicad_routable.dsn").read_text()
+    plain, _, _ = route_dsn_board(parse_dsn(text))
+    again, _, _ = route_dsn_board(parse_dsn(text), negotiate=0)
+    assert plain.unrouted == again.unrouted

tests/route/test_net_widths.py

@@ -0,0 +1,42 @@
+"""Net classes wider than the default are routed at their width where it fits."""
+
+from __future__ import annotations
+
+from freeroute.dsn import parse_dsn
+from freeroute.route.pipeline import build_exact_routing_result
+
+_BOARD = """(pcb widths (parser) (resolution um 10) (unit um)
+  (structure
+    (layer F.Cu (type signal))
+    (boundary (path pcb 0  0 0  20000 0  20000 -10000  0 -10000  0 0))
+    {keepouts}
+    (rule (width 150) (clearance 150)))
+  (placement (component S (place P1 2000 -5000 front 0) (place P2 18000 -5000 front 0)))
+  (library (image S (pin pad 1 0 0)) (padstack pad (shape (rect F.Cu -600 -600 600 600)) (attach off)))
+  (network (net PWR (pins P1-1 P2-1))
+    (class Power PWR (rule (width 400) (clearance 150)))))"""
+
+# two keepouts leave a 0.65 mm channel: room for 0.15 mm (0.45), not for 0.4 mm (0.7)
+_CHANNEL = (
+    '(keepout "" (polygon F.Cu 0  9000 0  11000 0  11000 -4675  9000 -4675))\n'
+    '    (keepout "" (polygon F.Cu 0  9000 -5325  11000 -5325  11000 -10000  9000 -10000))'
+)
+
+
+def _route(keepouts=""):
+    return build_exact_routing_result(parse_dsn(_BOARD.format(keepouts=keepouts)), resolution=2)
+
+
+def test_a_wider_class_is_routed_and_written_at_its_width():
+    result = _route()
+    assert result.unrouted == [] and result.narrowed == []
+    widths = {w.width for net in result.nets for w in net.wires}
+    assert widths == {400.0}
+
+
+def test_a_wider_class_that_does_not_fit_falls_back_to_the_default():
+    result = _route(_CHANNEL)
+    assert result.unrouted == []
+    assert [net for net, _a, _b in result.narrowed] == ["PWR"]
+    widths = {w.width for net in result.nets for w in net.wires}
+    assert widths == {150.0}

tests/route/test_orders.py

@@ -0,0 +1,78 @@
+"""--orders: route several connection orders and keep the best."""
+
+from __future__ import annotations
+
+from pathlib import Path
+
+from freeroute.cli import main
+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.
+RIPUP = (FIXTURES / "ripup_needed.dsn").read_text()
+GREEDY = {"rip_up": False}
+
+
+def test_the_default_order_is_always_a_candidate_without_a_seed():
+    assert candidate_seeds(1) == [None]
+    assert candidate_seeds(4) == [None, 0, 1, 2]
+    assert candidate_seeds(3, seed=7) == [7, 8, 9]
+
+
+def test_keeps_the_order_that_leaves_the_fewest_unrouted():
+    assert score(route_once(RIPUP, "grid", GREEDY, None)) == (1, 0)
+    result, kept, tried = best_of_orders(RIPUP, "grid", GREEDY, orders=3, jobs=2)
+    assert kept == 1
+    assert score(result) == (0, 0)
+    assert tried == [(None, (1, 0)), (0, (1, 0)), (1, (0, 0))]
+
+
+def test_ties_go_to_the_earlier_candidate():
+    # every order routes this board fully, so the default order is kept
+    _, kept, tried = best_of_orders(RIPUP, "grid", {}, orders=3, jobs=3)
+    assert kept is None
+    assert all(s == (0, 0) for _, s in tried)
+
+
+def test_cli_orders_writes_the_best_session(tmp_path, capsys):
+    out = tmp_path / "best.ses"
+    rc = main([str(FIXTURES / "ripup_needed.dsn"), "--no-rip-up", "--orders", "3", "-do", str(out)])
+    assert rc == 0
+    err = capsys.readouterr().err
+    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/route/test_real_board_geometry.py

@@ -0,0 +1,254 @@
+"""Routing behaviours found on the TerraHawk rc4 boards (2026-09-27)."""
+
+from __future__ import annotations
+
+import math
+
+import pytest
+
+from freeroute.board import build_board
+from freeroute.dsn import parse_dsn
+from freeroute.route.pipeline import route_dsn_board_exact
+
+# 20 x 20 mm board whose corners are rounded with a 3 mm radius, as polylines
+_R = 3000.0
+_arc = [(_R - _R * math.cos(math.radians(a)), _R - _R * math.sin(math.radians(a))) for a in range(0, 91, 15)]
+
+
+def _outline_coords():
+    pts = []
+    for cx, cy, sx, sy in ((0, 0, 1, 1), (20000, 0, -1, 1), (20000, -20000, -1, -1), (0, -20000, 1, -1)):
+        corner = [(cx + sx * x, cy - sy * y) for x, y in _arc]
+        pts.extend(corner if sx * sy > 0 else corner[::-1])
+    return " ".join(f"{x:.1f} {y:.1f}" for x, y in pts)
+
+
+def _dsn(placement, network, extra=""):
+    return f"""(pcb t (parser) (resolution um 10) (unit um)
+  (structure (layer F.Cu (type signal)) (layer B.Cu (type signal))
+    (boundary (path pcb 0 {_outline_coords()}))
+    (via "Via[0-1]_600:300_um") (rule (width 250) (clearance 150)) {extra})
+  (placement {placement})
+  (library (image P (pin pad 1 0 0))
+    (padstack pad (shape (rect F.Cu -150 -500 150 500)) (attach off))
+    (padstack "Via[0-1]_600:300_um" (shape (circle F.Cu 600)) (shape (circle B.Cu 600)) (attach off)))
+  (network {network}))"""
+
+
+def test_routes_keep_edge_clearance_at_a_rounded_corner():
+    # two pads near the top-left corner: the direct path cuts the corner arc
+    text = _dsn("(component P (place A 1800 -6000 front 0) (place B 6000 -1800 front 90))",
+                "(net N (pins A-1 B-1))")
+    dsn = parse_dsn(text)
+    result, scale, _ = route_dsn_board_exact(dsn, edge_clearance_mm=0.5)
+    assert result.routed_net_numbers
+    outline = build_board(dsn).outline
+    half = 125 * scale
+    for segs in result.result.wires.values():
+        for _layer, pts in segs:
+            for p in pts:
+                # every trace point, plus half the trace, keeps 0.5 mm to the edge
+                assert outline.edge_distance(p) >= half + 500 * scale - 1
+
+
+@pytest.mark.parametrize("resolution", [1, 4])
+def test_every_pin_of_a_half_millimetre_pitch_row_escapes(resolution):
+    # Five 0.3 mm pads at 0.5 mm pitch, each wired to its own pad 8 mm away.
+    # Between two neighbours a trace's centre has a legal band only 0.15 mm
+    # wide. At resolution 4 the 0.1 mm columns cannot miss it. At resolution
+    # 1 the 0.4 mm grid misses most bands, but a stub leaves its pin straight
+    # along the band and jogs to the column only past the pads, so every pin
+    # gets out there too, as the JAR manages (only 2 did before).
+    places = " ".join(f"(place R{i} {6000 + 500 * i} -6000 front 0)" for i in range(5))
+    places += " " + " ".join(f"(place F{i} {6000 + 500 * i} -14000 front 0)" for i in range(5))
+    nets = " ".join(f"(net N{i} (pins R{i}-1 F{i}-1))" for i in range(5))
+    result, _, _ = route_dsn_board_exact(
+        parse_dsn(_dsn(f"(component P {places})", nets)), resolution=resolution
+    )
+    assert len(result.routed_net_numbers) == 5
+    assert result.drc_clean
+
+
+def test_resolution_one_has_no_halo_so_the_grid_is_unchanged():
+    from freeroute.route.grid_router import GridRouter
+
+    board = build_board(parse_dsn(_dsn("", "")))
+    assert GridRouter(board, trace_width=2500, clearance=1500)._halo_offsets == []
+    fine = GridRouter(board, trace_width=2500, clearance=1500, resolution=2)
+    assert fine.step == 2000 and (1, 0) in fine._halo_offsets and (2, 0) not in fine._halo_offsets
+
+
+def test_heuristic_weight_bounds_route_length():
+    # weighted A* may take a longer route, but never more than W times the shortest
+    places = "(place A 3000 -3000 front 0) (place B 17000 -17000 front 0)"
+
+    def length(weight):
+        result, _, _ = route_dsn_board_exact(
+            parse_dsn(_dsn(f"(component P {places})", "(net N (pins A-1 B-1))")),
+            heuristic_weight=weight,
+        )
+        return sum(
+            math.hypot(q.x - p.x, q.y - p.y)
+            for segs in result.result.wires.values()
+            for _layer, pts in segs
+            for p, q in zip(pts, pts[1:], strict=False)
+        )
+
+    shortest = length(1.0)
+    assert shortest > 0
+    assert length(2.0) <= 2.0 * shortest
+
+
+# --- copper zones (DSN planes) -----------------------------------------------
+# rc4 power stage: pads inside "keep router off" pours connect through the pour,
+# and freeroute, not knowing zones, dropped every such connection.
+
+_ZONE = "(plane N (polygon F.Cu 0  4000 -4000  10000 -4000  10000 -10000  4000 -10000  4000 -4000))"
+_NO_TRACKS = "(wire_keepout \"pour\" (polygon F.Cu 0  4000 -4000  10000 -4000  10000 -10000  4000 -10000))"
+
+
+def _zone_board():
+    places = "(place P1 5500 -7000 front 0) (place P2 8500 -7000 front 0) (place P3 16000 -16000 front 0)"
+    return parse_dsn(_dsn(f"(component P {places})", "(net N (pins P1-1 P2-1 P3-1))", _ZONE + " " + _NO_TRACKS))
+
+
+def test_planes_are_read_and_are_not_obstacles():
+    dsn = _zone_board()
+    assert [(p.net, p.shape.layer) for p in dsn.planes] == [("N", "F.Cu")]
+    board = build_board(dsn)
+    assert len(board.get_conduction_areas()) == 1
+    assert all(not a.is_obstacle() or a.name == "pour" for a in board.get_obstacle_areas())
+
+
+def test_pads_in_one_zone_need_no_route_between_them():
+    from freeroute.route.grid_router import _connected_groups
+
+    board = build_board(_zone_board())
+    pins = sorted(board.get_pins(), key=lambda p: p.component_ref)
+    groups = _connected_groups(pins, board.get_conduction_areas())
+    assert [sorted(p.component_ref for p in g[0]) for g in groups] == [["P1", "P2"], ["P3"]]
+
+
+def test_a_pad_reaches_a_zone_under_a_no_tracks_area_by_a_via():
+    dsn = _zone_board()
+    result, scale, names = route_dsn_board_exact(dsn)
+    net = next(iter(result.routed_net_numbers))
+    assert result.result.vias.get(net)  # it had to drop into the zone
+    board = build_board(dsn)
+    pour = next(a for a in board.get_obstacle_areas() if a.name == "pour")
+    f_cu = names.index("F.Cu")
+    for layer, pts in result.result.wires[net]:
+        if layer == f_cu:  # no track runs inside the no-tracks area
+            assert not any(t.contains(p) and not t.bounding_box().is_empty()
+                           for t in pour.tiles for p in pts[1:-1])
+
+
+def test_a_pour_other_nets_can_cross_is_not_trusted_to_connect():
+    # the same zone with no no-tracks area over it: its fill could be split by
+    # other nets' tracks, so its pads are joined by routing, not assumed
+    places = "(place P1 5500 -7000 front 0) (place P2 8500 -7000 front 0)"
+    dsn = parse_dsn(_dsn(f"(component P {places})", "(net N (pins P1-1 P2-1))", _ZONE))
+    result, _, _ = route_dsn_board_exact(dsn)
+    net = next(iter(result.routed_net_numbers))
+    assert result.result.wires.get(net)  # P1 and P2 got a track between them
+
+
+def test_cli_names_the_connections_it_could_not_route(tmp_path, capsys):
+    # a keepout wall across the board on both layers: A and B cannot be joined
+    from freeroute.cli import main
+
+    wall = " ".join(
+        f"(keepout \"wall\" (polygon {layer} 0  9000 1000  11000 1000  11000 -21000  9000 -21000))"
+        for layer in ("F.Cu", "B.Cu")
+    )
+    dsn = tmp_path / "wall.dsn"
+    dsn.write_text(_dsn("(component P (place A 4000 -10000 front 0) (place B 16000 -10000 front 0))",
+                        "(net N (pins A-1 B-1))", wall))
+    assert main([str(dsn), "--engine", "exact", "-do", str(tmp_path / "out.ses")]) == 0
+    err = capsys.readouterr().err
+    assert "1 connection(s) not routed" in err and "N: A-1 to B-1" in err
+
+
+# --- inner plane layers (a 4-layer board with a GND plane on In1.Cu) --------
+
+def _four_layer_dsn():
+    return """(pcb four (parser) (resolution um 10) (unit um)
+  (structure
+    (layer F.Cu (type signal)) (layer In1.Cu (type power))
+    (layer In2.Cu (type power)) (layer B.Cu (type signal))
+    (boundary (path pcb 0  0 0  30000 0  30000 -30000  0 -30000  0 0))
+    (plane GND (polygon In1.Cu 0  500 -500  29500 -500  29500 -29500  500 -29500  500 -500))
+    (via "Via[0-3]_600:300_um") (rule (width 250) (clearance 150)))
+  (placement
+    (component S (place G1 5000 -5000 front 0) (place G2 25000 -5000 front 0)
+                 (place G3 15000 -25000 front 0) (place A 5000 -15000 front 0) (place B 25000 -15000 front 0))
+    (component T (place GT 15000 -15000 front 0)))
+  (library
+    (image S (pin smd 1 0 0))
+    (image T (pin tht 1 0 0))
+    (padstack smd (shape (rect F.Cu -300 -300 300 300)) (attach off))
+    (padstack tht (shape (circle F.Cu 1000)) (shape (circle B.Cu 1000)) (attach off))
+    (padstack "Via[0-3]_600:300_um" (shape (circle F.Cu 600)) (shape (circle B.Cu 600)) (attach off)))
+  (network (net GND (pins G1-1 G2-1 G3-1 GT-1)) (net SIG (pins A-1 B-1))))"""
+
+
+def test_smd_pads_reach_an_inner_plane_by_their_own_via():
+    dsn = parse_dsn(_four_layer_dsn())
+    result, scale, names = route_dsn_board_exact(dsn)
+    gnd = next(i + 1 for i, n in enumerate(dsn.nets) if n.name == "GND")
+    sig = next(i + 1 for i, n in enumerate(dsn.nets) if n.name == "SIG")
+    assert len(result.result.vias.get(gnd, [])) == 3  # one per SMD pad, none for the THT pad
+    for _layer, pts in result.result.wires.get(gnd, []):  # stubs, not tracks across the board
+        length = sum(abs(q.x - p.x) + abs(q.y - p.y) for p, q in zip(pts, pts[1:], strict=False))
+        assert length < 3000 * scale  # under 3 mm: a stub to its via
+    assert sig in result.result.routed_net_numbers  # signals still route on the outer layers
+    assert all(names[layer] in ("F.Cu", "B.Cu") for segs in result.result.wires.values() for layer, _ in segs)
+
+
+def test_a_pad_outside_the_plane_routes_to_it():
+    # G1 sits left of a plane that covers only the right half, so its route
+    # has to reach the plane's cells: those ends are the plane, not a pin
+    dsn_text = _four_layer_dsn().replace(
+        "(plane GND (polygon In1.Cu 0  500 -500  29500 -500  29500 -29500  500 -29500  500 -500))",
+        "(plane GND (polygon In1.Cu 0  15000 -500  29500 -500  29500 -29500  15000 -29500  15000 -500))",
+    )
+    result, _scale, _names = route_dsn_board_exact(parse_dsn(dsn_text))
+    gnd = next(i + 1 for i, n in enumerate(parse_dsn(dsn_text).nets) if n.name == "GND")
+    assert gnd in result.result.routed_net_numbers
+
+
+def test_a_through_hole_pad_inside_a_plane_needs_no_route():
+    from freeroute.route.grid_router import _connected_groups
+
+    board = build_board(parse_dsn(_four_layer_dsn()))
+    plane = [z for z in board.get_conduction_areas() if z.name == "GND"]
+    gnd_pins = [p for p in board.get_pins() if p.component_ref in ("G1", "G2", "G3", "GT")]
+    groups = _connected_groups(gnd_pins, plane, frozenset(id(z) for z in plane))
+    hub = next(g for g in groups if g[1])
+    assert [p.component_ref for p in hub[0]] == ["GT"]
+
+
+def test_a_pad_inside_a_via_keepout_reaches_the_plane_by_a_via_outside_it():
+    # a sensor's GND pad: vias are forbidden under the body, so the route
+    # has to leave on the top layer and drop to the plane past the keepout
+    dsn = parse_dsn("""(pcb repro (parser) (resolution um 10) (unit um)
+  (structure
+    (layer F.Cu (type signal)) (layer In1.Cu (type power)) (layer In2.Cu (type power))
+    (layer B.Cu (type signal))
+    (boundary (path pcb 0  0 0  20000 0  20000 -20000  0 -20000  0 0))
+    (plane GND (polygon In1.Cu 0  500 -500  19500 -500  19500 -19500  500 -19500  500 -500))
+    (via_keepout "" (polygon signal 0  8500 -8500  11500 -8500  11500 -11500  8500 -11500  8500 -8500))
+    (via "Via[0-3]_600:300_um") (rule (width 150) (clearance 150)))
+  (placement (component S (place G1 10000 -10000 front 0)))
+  (library
+    (image S (pin smd 1 0 0))
+    (padstack smd (shape (rect F.Cu -175 -300 175 300)) (attach off))
+    (padstack "Via[0-3]_600:300_um" (shape (circle F.Cu 600)) (shape (circle B.Cu 600)) (attach off)))
+  (network (net GND (pins G1-1))))""")
+    exact, scale, _names = route_dsn_board_exact(dsn, resolution=2)
+    assert exact.result.failed == []
+    (via,) = exact.result.vias[1]
+    half = 300 * scale  # the via's radius
+    outside = (via.x + half <= 8500 * scale or via.x - half >= 11500 * scale
+               or via.y - half >= -8500 * scale or via.y + half <= -11500 * scale)
+    assert outside, f"via at {via} is inside the via keepout"

tests/route/test_rollback.py

@@ -0,0 +1,43 @@
+"""--rollback: a rip-up that loses connections is undone, leaving no trace."""
+
+from __future__ import annotations
+
+from pathlib import Path
+
+import pytest
+
+from freeroute.board import build_board
+from freeroute.dsn import parse_dsn
+from freeroute.route.grid_router import GridRouter
+from freeroute.route.pipeline import _rule_clearance_dsn, _rule_width_dsn, route_dsn_board
+
+FIXTURES = Path(__file__).resolve().parent.parent / "dsn" / "fixtures"
+
+
+def _routed_router(name):
+    dsn = parse_dsn((FIXTURES / name).read_text())
+    s = dsn.resolution.value
+    router = GridRouter(
+        build_board(dsn),
+        trace_width=round(_rule_width_dsn(dsn) * s),
+        clearance=round(_rule_clearance_dsn(dsn) * s),
+        rollback=True,
+    )
+    return router, router.route()
+
+
+@pytest.mark.parametrize("name", ["ripup_needed.dsn", "true_density.dsn", "kicad_routable.dsn"])
+def test_occupancy_only_holds_routed_connections(name):
+    router, _ = _routed_router(name)
+    conns = router._conns
+    assert all(conns[i].routed for i in router._cell_owner.values())
+    assert all(conns[i].routed for claims in router._via_claims.values() for i in claims)
+    assert all(conns[i].routed for claims in router._halo.values() for i in claims)
+
+
+@pytest.mark.parametrize("name", ["ripup_needed.dsn", "true_density.dsn", "kicad_routable.dsn"])
+def test_rollback_never_routes_fewer_than_plain_rip_up(name):
+    text = (FIXTURES / name).read_text()
+    plain, _, _ = route_dsn_board(parse_dsn(text), rollback=False)
+    undo, _, _ = route_dsn_board(parse_dsn(text))
+    assert undo.unrouted <= plain.unrouted

tests/route/test_router.py

@@ -264,6 +264,19 @@ def test_larger_board_still_connects_its_multipin_nets():
     assert len(result.routed_net_numbers) == multi_pin == 4
 
 
+def test_a_seed_is_repeatable_and_does_change_the_order():
+    # The benchmark samples seeds to measure how much a result owes to the
+    # routing order. A seed that changed nothing would make every sample the
+    # same run and report no spread at all.
+    text = (FIXTURES / "kicad_routable.dsn").read_text()
+    default = _wire_key(route_dsn_board(parse_dsn(text))[0])
+    runs = {s: route_dsn_board(parse_dsn(text), seed=s)[0] for s in range(4)}
+    again = route_dsn_board(parse_dsn(text), seed=1)[0]
+    assert _wire_key(again) == _wire_key(runs[1])
+    assert any(_wire_key(r) != default for r in runs.values())
+    assert all(r.unrouted == 0 for r in runs.values())
+
+
 # --- oracle parity ----------------------------------------------------------
 
 

tests/route/test_straight_pin_exits.py

@@ -0,0 +1,58 @@
+"""Pins of a 1.27 mm pitch row routed at 1.0 mm (the RN2483 module on the
+TTN Enschede mote). A trace centre has to stay within 0.06 mm of a pin's
+centreline to pass its neighbours, which no grid column hits, so a route
+leaves each pin straight along that line and only jogs to its column once
+past the pads. FreeRouting routes this row in full the same way."""
+
+from __future__ import annotations
+
+import pytest
+
+from freeroute.board import build_board
+from freeroute.board.items import Pin
+from freeroute.dsn import parse_dsn
+from freeroute.geometry import IntPoint
+from freeroute.route.grid_router import GridRouter
+from freeroute.route.pipeline import route_dsn_board_exact
+
+
+def _row(x0: int, pins: int = 6, skew: int = 3000) -> str:
+    places = " ".join(f"(place R{i} {x0 + 1270 * i} -5000 front 0)" for i in range(pins))
+    places += " " + " ".join(
+        f"(place T{i} {x0 + 1270 * i + skew} -15000 front 0)" for i in range(pins)
+    )
+    nets = " ".join(f"(net N{i} (pins R{i}-1 T{i}-1))" for i in range(pins))
+    return f"""(pcb t (parser) (resolution um 10) (unit um)
+  (structure (layer F.Cu (type signal)) (layer B.Cu (type signal))
+    (boundary (path pcb 0 0 0 30000 0 30000 -20000 0 -20000 0 0))
+    (via "Via[0-1]_600:400_um") (rule (width 1000) (clearance 200)))
+  (placement (component P {places}))
+  (library (image P (pin pad 1 0 0))
+    (padstack pad (shape (rect F.Cu -508 -762 508 762)) (attach off))
+    (padstack "Via[0-1]_600:400_um" (shape (circle F.Cu 600)) (shape (circle B.Cu 600))
+      (attach off)))
+  (network {nets}))"""
+
+
+@pytest.mark.parametrize("x0", [5000, 5150, 5300])
+def test_every_pin_of_a_row_leaves_straight_and_routes(x0):
+    # three offsets of the row against the grid; before, 2 or 3 of 6 routed
+    result, _, _ = route_dsn_board_exact(parse_dsn(_row(x0)), resolution=2)
+    assert len(result.routed_net_numbers) == 6
+    assert result.drc_clean
+
+
+def test_a_walled_in_pin_may_escape_to_the_column_either_side():
+    # two pins side by side leaving the same way can then jog apart
+    board = build_board(parse_dsn(_row(5000)))
+    router = GridRouter(board, trace_width=10000, clearance=2000, orthogonal=True, resolution=2)
+    router._conns = router._build_connections()
+    pin = next(
+        p for p in board.get_items()
+        if isinstance(p, Pin) and p.location == IntPoint(50000 + 2 * 12700, -50000)
+    )
+    net = pin.net_nos[0]
+    cx, cy = router._cell_of(pin.location)
+    nodes = router._escape_nodes(pin, net, router._conns, [0], (cx, cy))
+    columns = {x for x, y, _ in nodes if y != cy}
+    assert {cx - 1, cx, cx + 1} <= columns

tests/route/test_tree_nets.py

@@ -0,0 +1,170 @@
+"""Multi-pin nets: spanning-tree pairs, and connections that end on copper
+their net has already routed (a T into the tree)."""
+
+from __future__ import annotations
+
+import pytest
+
+from freeroute.board import build_board
+from freeroute.dsn import parse_dsn
+from freeroute.route import exact_router
+from freeroute.route.grid_router import GridRouter, RouteResult
+from freeroute.route.pipeline import _rule_clearance_dsn, _rule_width_dsn
+
+# P1 and P2 are nearest each other, so the tree pairs them first; P3 sits
+# under the middle of that leg, 50 mm below it and 90 mm from either pin.
+TEE = """(pcb "tee.dsn"
+  (parser (string_quote ") (space_in_quoted_tokens on) (host_cad "t") (host_version "1"))
+  (resolution um 10)
+  (unit um)
+  (structure
+    (layer F.Cu (type signal) (property (index 0)))
+    (boundary (path pcb 0  0 0  200000 0  200000 -100000  0 -100000  0 0))
+    (rule (width 2000) (clearance 2000))
+  )
+  (library
+    (padstack Rect_Pad (shape (rect F.Cu -1000 -1000 1000 1000)) (attach off))
+    (image PAD (pin Rect_Pad 1 0 0))
+  )
+  (placement
+    (component PAD
+      (place P1 60000 -20000 front 0)
+      (place P2 140000 -20000 front 0)
+      (place P3 100000 -70000 front 0)
+    )
+  )
+  (network
+    (net N (pins P1-1 P2-1 P3-1))
+    (class default (rule (width 2000) (clearance 2000)))
+  )
+  (wiring)
+)
+"""
+
+
+def _router(tree_nets=True, text=TEE):
+    dsn = parse_dsn(text)
+    s = dsn.resolution.value
+    return GridRouter(
+        build_board(dsn),
+        trace_width=round(_rule_width_dsn(dsn) * s),
+        clearance=round(_rule_clearance_dsn(dsn) * s),
+        orthogonal=True,
+        tree_nets=tree_nets,
+    )
+
+
+def test_pairs_follow_a_spanning_tree_not_the_pin_order():
+    router = _router()
+    conns = router._build_connections()
+    pairs = [(c.a.component_ref, c.b.component_ref) for c in conns]
+    assert pairs == [("P1", "P2"), ("P1", "P3")]
+    chain = _router(tree_nets=False)._build_connections()
+    assert [(c.a.component_ref, c.b.component_ref) for c in chain] == [("P1", "P2"), ("P2", "P3")]
+
+
+def test_the_third_pin_tees_into_the_first_leg():
+    router = _router()
+    result = router.route()
+    first, second = router._conns
+    assert result.unrouted == 0
+    # the second connection starts on the first one's copper, mid-leg
+    start = second.path[0]
+    assert start in first.copper and second.a_end is None
+    assert second.anchors == {first.index}
+    assert router._dependents[first.index] == {second.index}
+    assert abs(router._cell_center(start[:2]).x - 1_000_000) <= router.step
+    # and so its copper is the 50 mm drop, not 90 mm back to a pin
+    assert len(second.path) < len(router._conns[0].path)
+
+
+def test_without_trees_each_connection_ends_on_a_pin():
+    router = _router(tree_nets=False)
+    router.route()
+    assert all(c.anchors == frozenset() for c in router._conns)
+    assert all(c.a_end is not None and c.b_end is not None for c in router._conns)
+
+
+def test_ripping_an_anchor_takes_what_hangs_on_it():
+    router = _router()
+    router.route()
+    first, second = router._conns
+    victims = router._with_dependents([first], router._conns)
+    assert victims == [first, second]  # anchors first, as committed
+    for victim in victims:
+        router._rip(victim)
+    assert not first.routed and not second.routed
+    assert not router._dependents.get(first.index)
+    assert not router._cell_owner
+
+
+def test_the_snapshot_lists_anchors_before_what_hangs_on_them():
+    router = _router()
+    result = router.route()
+    assert result.connection_anchors == [(), (0,)]
+
+
+def test_the_exact_engine_drops_a_tee_whose_anchor_it_rejects(monkeypatch):
+    """A connection teed onto copper the exact check refuses would dangle."""
+    dsn = parse_dsn(TEE)
+    board = build_board(dsn)
+    real = exact_router.route_board
+
+    def grid_then_spoil(*args, **kwargs):
+        result: RouteResult = real(*args, **kwargs)
+        assert result.connection_anchors == [(), (0,)]
+        # move the first leg off the board edge so the exact check rejects it
+        net, wires, vias = result.connections[0]
+        result.connections[0] = (net, [(layer, [type(p)(p.x, p.y + 2_000_000) for p in pts])
+                                       for layer, pts in wires], vias)
+        return result
+
+    monkeypatch.setattr(exact_router, "route_board", grid_then_spoil)
+    s = dsn.resolution.value
+    exact = exact_router.route_board_exact(
+        board,
+        trace_width=round(_rule_width_dsn(dsn) * s),
+        clearance=round(_rule_clearance_dsn(dsn) * s),
+    )
+    assert len(exact.result.failed) == 2  # the leg and the T hanging on it
+    assert not exact.result.wires
+
+
+@pytest.mark.parametrize("tree_nets", [True, False])
+def test_occupancy_stays_honest(tree_nets):
+    router = _router(tree_nets)
+    router.route()
+    conns = router._conns
+    assert all(conns[i].routed for i in router._cell_owner.values())
+    for anchor, hanging in router._dependents.items():
+        for i in hanging:
+            assert conns[i].routed and conns[anchor].routed
+
+
+# P1-P2 along the top, P3 far off to the lower right, P4 just under the
+# middle of the P1-P2 leg.
+CHAIN_TEE = TEE.replace(
+    """      (place P3 100000 -70000 front 0)
+""",
+    """      (place P3 190000 -90000 front 0)
+      (place P4 100000 -40000 front 0)
+""",
+).replace("(pins P1-1 P2-1 P3-1)", "(pins P1-1 P2-1 P3-1 P4-1)")
+
+
+def test_a_tee_depends_on_every_connection_back_to_its_group():
+    """Joined as P1-P2, P2-P3, P3-P4, P4's connection tees onto P1-P2 copper,
+    which reaches P3's group only through P2-P3. Ripping P2-P3 must take the T
+    too, or it would be counted routed while cut off from P3."""
+    router = _router(text=CHAIN_TEE)
+    conns = router._conns = router._build_connections()
+    groups = {c.a.component_ref: c.a_group for c in conns}
+    groups.update({c.b.component_ref: c.b_group for c in conns})
+    for conn, (a, b) in zip(conns, (("P1", "P2"), ("P2", "P3"), ("P3", "P4")), strict=True):
+        conn.a_group, conn.b_group = groups[a], groups[b]
+    for conn in conns:
+        assert router._try_route(conn, conns)
+    first, second, third = conns
+    assert third.path[0] in first.copper  # the T lands on the far leg
+    assert third.anchors == {first.index, second.index}
+    assert router._with_dependents([second], conns) == [second, third]

tests/route/test_via_spacing.py

@@ -0,0 +1,136 @@
+"""Vias keep hole-to-hole spacing, even within one net."""
+
+from __future__ import annotations
+
+import itertools
+import math
+
+from freeroute.dsn import parse_dsn
+from freeroute.route.pipeline import route_dsn_board_exact
+
+# four GND pads 0.5 mm apart over a GND plane: each drops a via to the plane
+_DSN = """(pcb holes (parser) (resolution um 10) (unit um)
+  (structure
+    (layer F.Cu (type signal)) (layer In1.Cu (type power)) (layer In2.Cu (type power))
+    (layer B.Cu (type signal))
+    (boundary (path pcb 0  0 0  20000 0  20000 -20000  0 -20000  0 0))
+    (plane GND (polygon In1.Cu 0  500 -500  19500 -500  19500 -19500  500 -19500  500 -500))
+    (via "Via[0-3]_500:300_um") (rule (width 150) (clearance 150)))
+  (placement (component S (place G1 9000 -10000 front 0) (place G2 9500 -10000 front 0)
+                          (place G3 10000 -10000 front 0) (place G4 10500 -10000 front 0)))
+  (library
+    (image S (pin smd 1 0 0))
+    (padstack smd (shape (rect F.Cu -150 -300 150 300)) (attach off))
+    (padstack "Via[0-3]_500:300_um" (shape (circle F.Cu 500)) (shape (circle B.Cu 500)) (attach off)))
+  (network (net GND (pins G1-1 G2-1 G3-1 G4-1))))"""
+
+
+def test_a_nets_own_vias_keep_hole_to_hole_spacing():
+    dsn = parse_dsn(_DSN)
+    exact, scale, _ = route_dsn_board_exact(dsn, resolution=2)
+    assert exact.result.failed == []
+    vias = exact.result.vias[1]
+    assert len(set(vias)) == len(vias), "a via written twice"
+    need = (300 + 250) * scale  # drill + 0.25 mm, centre to centre
+    for a, b in itertools.combinations(vias, 2):
+        assert math.hypot(a.x - b.x, a.y - b.y) >= need, f"vias at {a} and {b} too close"
+
+
+def test_connections_sharing_a_plane_via_write_it_once():
+    # eight GND pads 0.4 mm apart: the hole spacing makes several of them
+    # end on the same plane via, which must come out once, not once each
+    pads = " ".join(f"(place G{i} {9000 + 400 * i} -10000 front 0)" for i in range(8))
+    pins = " ".join(f"G{i}-1" for i in range(8))
+    dsn = parse_dsn(
+        _DSN.replace(
+            "(place G1 9000 -10000 front 0) (place G2 9500 -10000 front 0)\n"
+            "                          (place G3 10000 -10000 front 0) (place G4 10500 -10000 front 0)",
+            pads,
+        )
+        .replace("(pins G1-1 G2-1 G3-1 G4-1)", f"(pins {pins})")
+        .replace("(rect F.Cu -150 -300 150 300)", "(rect F.Cu -125 -300 125 300)")
+    )
+    exact, _scale, _ = route_dsn_board_exact(dsn, resolution=2)
+    vias = exact.result.vias[1]
+    assert len(vias) < 8, "no via is shared, so this board no longer tests sharing"
+    assert len(set(vias)) == len(vias), "a shared via written more than once"
+
+
+def _router(dsn_text, via_drill_um=300):
+    from freeroute.board import build_board
+    from freeroute.route.grid_router import GridRouter
+    from freeroute.route.pipeline import _rule_clearance_dsn, _rule_width_dsn
+
+    dsn = parse_dsn(dsn_text)
+    s = dsn.resolution.value
+    return GridRouter(
+        build_board(dsn), trace_width=round(_rule_width_dsn(dsn) * s),
+        clearance=round(_rule_clearance_dsn(dsn) * s), resolution=2, orthogonal=True,
+        via_drill=via_drill_um * s, hole_to_hole=250 * s,
+    ), s
+
+
+_THT = """(pcb tht (parser) (resolution um 10) (unit um)
+  (structure (layer F.Cu (type signal)) (layer B.Cu (type signal))
+    (boundary (path pcb 0  0 0  20000 0  20000 -20000  0 -20000  0 0))
+    (via "Via[0-1]_500:300_um") (rule (width 150) (clearance 150)))
+  (placement (component T (place J1 10000 -10000 front 0)))
+  (library (image T (pin tht 1 0 0))
+    (padstack tht (shape (circle F.Cu 1700)) (shape (circle B.Cu 1700)) (attach off))
+    (padstack "Via[0-1]_500:300_um" (shape (circle F.Cu 500)) (shape (circle B.Cu 500)) (attach off)))
+  (network (net SIG (pins J1-1))))"""
+
+
+def test_no_via_goes_near_a_through_hole_pads_hole_even_of_its_own_net():
+    router, s = _router(_THT)
+    pin = router._cell_of(router.board.get_pins()[0].location)
+    assert not router._holes_clear(pin, 1)  # own net, right on the pad
+    far = (pin[0] + 40, pin[1])
+    assert router._holes_clear(far, 1)
+
+
+def test_a_via_in_a_pad_keeps_hole_spacing_from_a_fixed_via():
+    from freeroute.geometry import IntPoint
+
+    text = _THT.replace("(network (net SIG (pins J1-1))))",
+                        "(network (net SIG (pins J1-1)))\n"
+                        "  (wiring (via \"Via[0-1]_500:300_um\"  3000 -3000 (net SIG) (type route))))")
+    router, s = _router(text)
+    assert not router._hole_clear_at(IntPoint(3400 * s, -3000 * s))  # 0.4 mm < 0.55 mm
+    assert router._hole_clear_at(IntPoint(3600 * s, -3000 * s))
+
+
+def test_hole_spacing_from_a_fixed_via_is_measured_from_where_it_really_is():
+    # a fixed via off the grid with its own 0.25 mm drill, and the router's
+    # via a smaller 0.2 mm one (the flight controller's case): a new via needs
+    # its centre 0.1 + 0.125 + 0.25 = 0.475 mm away, measured exactly, where
+    # one rule for all vias gave 0.2 + 0.25 = 0.45 from the cell centres
+    text = _THT.replace("(network (net SIG (pins J1-1))))",
+                        "(network (net SIG (pins J1-1)) (net GND))\n"
+                        "  (wiring (via \"Via[0-1]_500:250_um\"  3030 -3030 (net GND) (type route))))")
+    text = text.replace(
+        '(attach off)))\n  (network',
+        '(attach off))\n    (padstack "Via[0-1]_500:250_um" (shape (circle F.Cu 500)) '
+        '(shape (circle B.Cu 500)) (attach off)))\n  (network',
+    )
+    router, s = _router(text, via_drill_um=200)
+    via = next(v for v in router.board.get_items() if getattr(v, "drill", 0))
+    assert via.drill == 250 * s
+    loc = via.location
+    for cell in [(x, y) for x in range(router.cols) for y in range(router.rows)]:
+        c = router._cell_center(cell)
+        d = math.hypot(c.x - loc.x, c.y - loc.y)
+        if router.step * 1.5 < d < 470 * s:
+            assert not router._holes_clear(cell, 1), f"{d / s:.0f} um from the fixed via"
+        elif 560 * s < d < 700 * s and cell not in router._tht_block:
+            assert router._holes_clear(cell, 1)
+
+
+def test_a_route_keeps_its_own_vias_apart():
+    # a route that changed layer at (10, 10) may not change layer again one
+    # cell away; the same cell is the same through via, and far is fine
+    router, _s = _router(_THT)
+    came_from = {(10, 10, 1): (10, 10, 0), (11, 10, 1): (10, 10, 1), (12, 10, 1): (11, 10, 1)}
+    assert router._near_path_via((12, 10, 1), (11, 10), came_from)
+    assert not router._near_path_via((12, 10, 1), (10, 10), came_from)
+    assert not router._near_path_via((12, 10, 1), (40, 10), came_from)

tests/route/test_window_reroute.py

@@ -0,0 +1,128 @@
+"""Window re-route: a finer grid around a stuck connection, kept only when
+it leaves fewer connections unrouted."""
+
+from __future__ import annotations
+
+from freeroute.board import build_board
+from freeroute.dsn import parse_dsn
+from freeroute.geometry import IntBox
+from freeroute.route.grid_router import GridRouter
+from freeroute.route.pipeline import _rule_clearance_dsn, _rule_width_dsn, route_dsn_board_exact
+
+
+def _slot(gap: int = 640, far: bool = False) -> str:
+    """A wall across the board with a slot in it. A trace fits the slot
+    only along a narrow band of heights that the board's 1x grid has no row
+    in and a 4x grid does. ``far`` adds a second net nowhere near the wall."""
+    yc = -5000
+    lo, hi = yc - gap // 2, yc + gap // 2
+    extra_place = "(place Q1 2000 -1000 front 0) (place Q2 6000 -1000 front 0)" if far else ""
+    extra_net = "(net M (pins Q1-1 Q2-1))" if far else ""
+    return f"""(pcb "slot.dsn"
+  (parser (string_quote ") (space_in_quoted_tokens on) (host_cad "t") (host_version "1"))
+  (resolution um 10)
+  (unit um)
+  (structure
+    (layer F.Cu (type signal) (property (index 0)))
+    (boundary (path pcb 0  0 0  20000 0  20000 -10000  0 -10000  0 0))
+    (keepout "" (rect F.Cu 9000 -10000 11000 {lo}))
+    (keepout "" (rect F.Cu 9000 {hi} 11000 0))
+    (rule (width 200) (clearance 200))
+  )
+  (library
+    (padstack Rect_Pad (shape (rect F.Cu -100 -100 100 100)) (attach off))
+    (image PAD (pin Rect_Pad 1 0 0))
+  )
+  (placement
+    (component PAD
+      (place P1 3000 {yc} front 0)
+      (place P2 17000 {yc} front 0)
+      {extra_place}
+    )
+  )
+  (network
+    (net N (pins P1-1 P2-1))
+    {extra_net}
+    (class default (rule (width 200) (clearance 200)))
+  )
+  (wiring)
+)
+"""
+
+
+def _route(text: str, rounds: int, **window):
+    exact, _scale, _layers = route_dsn_board_exact(
+        parse_dsn(text), resolution=1, window_reroute=rounds, window_resolution=4, **window,
+    )
+    return exact.result
+
+
+def test_the_board_grid_misses_the_slot_and_a_finer_window_finds_it():
+    plain = _route(_slot(), 0)
+    assert len(plain.failed) == 1
+    windowed = _route(_slot(), 1)
+    assert windowed.failed == []
+    assert windowed.wires  # and the copper it found is in the result
+
+
+def test_a_window_that_cannot_help_leaves_the_board_as_it_was():
+    plain = _route(_slot(gap=500, far=True), 0)  # too narrow for any grid
+    windowed = _route(_slot(gap=500, far=True), 2)
+    assert len(windowed.failed) == len(plain.failed) == 1
+    assert windowed.wires == plain.wires
+    assert windowed.vias == plain.vias
+
+
+def test_copper_outside_the_window_is_kept_as_it_was():
+    plain = _route(_slot(far=True), 0)
+    windowed = _route(_slot(far=True), 1)
+    assert windowed.failed == []
+    far_net = 2  # M, the second net in the DSN
+    assert windowed.wires[far_net] == plain.wires[far_net]
+
+
+def test_a_router_limited_to_some_nets_and_a_box_builds_only_those():
+    dsn = parse_dsn(_slot(far=True))
+    s = dsn.resolution.value
+    board = build_board(dsn)
+    whole = GridRouter(board, trace_width=round(_rule_width_dsn(dsn) * s),
+                       clearance=round(_rule_clearance_dsn(dsn) * s), orthogonal=True)
+    part = GridRouter(board, trace_width=round(_rule_width_dsn(dsn) * s),
+                      clearance=round(_rule_clearance_dsn(dsn) * s), orthogonal=True,
+                      only_nets=frozenset({2}), bounds=IntBox(0, -20000, 80000, 0))
+    assert {c.net_no for c in whole._build_connections()} == {1, 2}
+    assert {c.net_no for c in part._build_connections()} == {2}
+    assert part.cols * part.rows < whole.cols * whole.rows
+
+
+def test_a_spent_budget_starts_no_window():
+    assert len(_route(_slot(), 1, window_budget=0.0).failed) == 1
+    assert _route(_slot(), 1, window_budget=1000.0).failed == []
+
+
+def test_window_board_keeps_far_items_of_the_rerouted_nets_only():
+    from freeroute.route.window import _item_box, _window_board
+
+    board = build_board(parse_dsn(_slot(far=True)))
+    items = [(item, _item_box(item)) for item in board.get_items()]
+    view = IntBox(80000, -60000, 120000, -40000)  # around the slot, far from Q1/Q2
+    sub = _window_board(board, items, view, {1}, {}, set(), {}, 100, 300, 300, [0], "via")
+    refs = {p.component_ref for p in sub.get_pins()}
+    assert {"P1", "P2"} <= refs  # net N's pins, though outside the view
+    assert not refs & {"Q1", "Q2"}  # net M's, far away, left out
+
+
+def test_a_connection_ending_outside_the_window_gets_no_copper():
+    """Its far end has no grid cells; a stub out to it would cross items the
+    window board never saw."""
+    from freeroute.route.exact_router import route_board_exact
+
+    dsn = parse_dsn(_slot(far=True))
+    s = dsn.resolution.value
+    window = IntBox(70000, -70000, 130000, -30000)  # the slot only; net M's pins are far off
+    result = route_board_exact(
+        build_board(dsn), trace_width=round(_rule_width_dsn(dsn) * s),
+        clearance=round(_rule_clearance_dsn(dsn) * s), only_nets=frozenset({2}), bounds=window,
+    ).result
+    assert [f[0] for f in result.failed] == [2]
+    assert not result.wires.get(2) and not result.vias.get(2)

tests/test_cli.py

@@ -154,6 +154,14 @@ def test_cli_supported_combinations_are_accepted(tmp_path):
         "diagonal": ["--diagonal"],
         "rip_up": ["--no-rip-up"],
         "max_passes": ["-mp", "4"],
+        "seed": ["--seed", "3"],
+        "orders": ["--orders", "2"],
+        "promote": ["--promote-failures", "2"],
+        "access": ["--access-cost", "5"],
+        "negotiate": ["--negotiate", "2"],
+        "rollback": ["--no-rollback"],
+        "tree": ["--no-tree"],
+        "window": ["--window-reroute", "1"],
     }
     for engine, options in ENGINE_OPTIONS.items():
         for option in options:

uv.lock

@@ -128,7 +128,7 @@ wheels = [
 
 [[package]]
 name = "freeroute"
-version = "0.1.0"
+version = "2026.7.14"
 source = { editable = "." }
 
 [package.dev-dependencies]