KiCad 10 fix (some file names have changed)

.github/workflows/test-check-all.yaml

@@ -26,6 +26,9 @@ jobs:
     steps:
       - uses: actions/checkout@v5
 
+      - name: Check KiCad Gerber naming and cleanup
+        run: python3 -m unittest discover -s tests -p 'test_kicad_gerbers.py'
+
       - name: Install kicad 10
         run: |
           sudo add-apt-repository --yes ppa:kicad/kicad-10.0-releases

bin/cleanup_kicad_gerbers.py

@@ -0,0 +1,33 @@
+#!/usr/bin/env python3
+"""Remove obsolete KiCad 8 inner-layer exports when KiCad 10 replacements exist."""
+
+import argparse
+from pathlib import Path
+
+
+def cleanup(directory, board, dry_run=False):
+    for layer in (1, 2):
+        current = directory / (board + "-In%d_Cu.g%d" % (layer, layer))
+        obsolete = directory / (board + "-In%d_Cu.g%d" % (layer, layer + 1))
+        if current.is_file() and obsolete.is_file():
+            print("%s %s (replaced by %s)" % (
+                "Would remove" if dry_run else "Removing", obsolete, current.name))
+            if not dry_run:
+                obsolete.unlink()
+
+
+def main():
+    parser = argparse.ArgumentParser(description=__doc__)
+    parser.add_argument("directory", type=Path, help="Gerber export directory")
+    parser.add_argument("board", help="PCB basename, e.g. uaefi-pro")
+    parser.add_argument("--dry-run", action="store_true", help="Only list obsolete files")
+    args = parser.parse_args()
+    if not args.directory.is_dir():
+        parser.error("Gerber directory does not exist: %s" % args.directory)
+    if not args.board or Path(args.board).name != args.board or args.board in (".", ".."):
+        parser.error("board must be a basename without a directory")
+    cleanup(args.directory, args.board, args.dry_run)
+
+
+if __name__ == "__main__":
+    main()

bin/copy_from_Kicad.py

@@ -65,24 +65,28 @@ def mkdir_p(path):
 print ("Reading gerbers from " + src_name + "*.*")
 gerbers = [ ".GTL", ".GTO", ".GTP", ".GTS", ".GBL", ".GBO", ".GBS", ".GBP", ".GM1", ".DRL" ]
 if (num_layers >= 4):
-	gerbers += [ ".G2", ".G3" ]
+	# Match logical layer names: KiCad 8 used g2/g3, KiCad 10 uses g1/g2.
+	# An extension-only glob can copy In2 over In1 when both exports coexist.
+	current_inner = [src_name + "-In%d_Cu.g%d" % (i, i) for i in (1, 2)]
+	legacy_inner = [src_name + "-In%d_Cu.g%d" % (i, i + 1) for i in (1, 2)]
+	inner = current_inner if any(os.path.isfile(p) for p in current_inner) else legacy_inner
+	if any(os.path.isfile(p) for p in inner):
+		if not all(os.path.isfile(p) for p in inner):
+			print ("Error! Incomplete internal Gerber layer pair: " + ", ".join(inner))
+			sys.exit(2)
+		gerbers += [ ".G1", ".G2" ]
 for g in gerbers:
 	copied = False
 	gl = g.lower()
-	for gPath in glob.glob(src_name + "*" + gl):
+	paths = [inner[int(g[2:]) - 1]] if g in (".G1", ".G2") else glob.glob(src_name + "*" + gl)
+	for gPath in paths:
 		print ("* Copying " + name + gl + "...")
 		# keepout layer is a special case
 		if (g == ".GM1"):
 			# currently the "edge cuts" layer is used as a frame border
 			if (type == "frames"):
 				shutil.copyfile(gPath, dst_name + ".GM15")
 			shutil.copyfile(gPath, dst_name + ".GKO")
-		elif (g == ".G2"):
-			# using Altium naming convention
-			shutil.copyfile(gPath, dst_name + ".G1")
-		elif (g == ".G3"):
-			# using Altium naming convention
-			shutil.copyfile(gPath, dst_name + ".G2")
 		else:
 			shutil.copyfile(gPath, dst_name + g)
 		copied = True
@@ -91,8 +95,6 @@ def mkdir_p(path):
 			print ("* Skipping Drill for " + name + "...")
 		elif (g == ".GBP"):
 			print ("* Skipping Bottom Paste for " + name + "...")
-		elif (g == ".G2" or g == ".G3"):
-			print ("* Skipping Internal Layer " + g + " for " + name + "...")
 		else:
 			print ("Error! Gerber " + g + " not found for " + name + "!")
 			sys.exit(2)

kicad/bin/export.sh

@@ -63,6 +63,7 @@ $PYTHON "$DIR/../hellen-one-kicad-bom-plugin.py" "$NET_FILE" "$OUT_FOLDER/$IN.cs
 
 echo Export Gerbers with zones refilled in-memory
 $KICAD_CLI pcb export gerbers --disable-aperture-macros -l "F.Cu,B.Cu,F.Paste,B.Paste,F.SilkS,B.SilkS,F.Mask,B.Mask,Edge.Cuts,In2.Cu,In1.Cu" --no-x2 --use-drill-file-origin --check-zones "$PCB_FILE" -o $OUT_FOLDER/
+$PYTHON "$DIR/../../bin/cleanup_kicad_gerbers.py" "$OUT_FOLDER" "$IN"
 echo Export drill file
 $KICAD_CLI pcb export drill --map-format ps --drill-origin plot --excellon-zeros-format suppressleading -u "in" "$PCB_FILE" -o $OUT_FOLDER/
 echo Export positions file

kicad/readme.md

@@ -17,3 +17,16 @@ Local run for the test frame:
 ```
 cd tests && bash ../kicad/bin/export.sh
 ```
+
+KiCad 8 named the inner layers `In1_Cu.g2` / `In2_Cu.g3`; KiCad 10 uses
+`In1_Cu.g1` / `In2_Cu.g2`. Export automatically removes the obsolete filenames
+when their replacements exist. To clean an existing board export manually:
+
+```
+python3 hellen-one/bin/cleanup_kicad_gerbers.py gerber uaefi-pro --dry-run
+python3 hellen-one/bin/cleanup_kicad_gerbers.py gerber uaefi-pro
+```
+
+The copy step selects inner layers by full layer name and prefers the KiCad 10
+pair, while still accepting a KiCad 8 pair. Regenerate the board outputs after
+cleaning an export that contained both versions.

tests/test_kicad_gerbers.py

@@ -0,0 +1,95 @@
+"""Regression checks for mixed KiCad 8 and KiCad 10 inner-layer exports."""
+
+from pathlib import Path
+import shutil
+import subprocess
+import sys
+import tempfile
+import unittest
+
+
+ROOT = Path(__file__).resolve().parents[1]
+
+
+class KicadGerberTests(unittest.TestCase):
+    def setUp(self):
+        self.temp = tempfile.TemporaryDirectory(prefix="kicad gerbers ")
+        self.addCleanup(self.temp.cleanup)
+        self.project = Path(self.temp.name)
+        self.gerber = self.project / "gerber"
+        shutil.copytree(ROOT / "tests/gerber", self.gerber)
+
+    def write_layers(self, version):
+        for layer in (1, 2):
+            extension = layer if version == 10 else layer + 1
+            (self.gerber / ("hellen1test-In%d_Cu.g%d" % (layer, extension))).write_text(
+                "KiCad %d layer %d" % (version, layer))
+
+    def run_script(self, script, *args):
+        return subprocess.run(
+            [sys.executable, str(ROOT / "bin" / script), *map(str, args)],
+            cwd=ROOT, capture_output=True, text=True)
+
+    def copy_frame(self):
+        return self.run_script("copy_from_Kicad.py", "frames:hellen", self.project,
+                               "../../gerber", "1test", "a", "4")
+
+    def assert_layers(self, version):
+        result = self.copy_frame()
+        self.assertEqual(result.returncode, 0, result.stdout + result.stderr)
+        frame = self.project / "boards/hellen1test-a/frame"
+        for layer in (1, 2):
+            self.assertEqual((frame / ("1test.G%d" % layer)).read_text(),
+                             "KiCad %d layer %d" % (version, layer))
+
+    def test_legacy_export(self):
+        self.write_layers(8)
+        self.assert_layers(8)
+
+    def test_current_export(self):
+        self.write_layers(10)
+        self.assert_layers(10)
+
+    def test_mixed_exports_prefer_current_in_either_creation_order(self):
+        for versions in ((8, 10), (10, 8)):
+            with self.subTest(versions=versions):
+                for path in self.gerber.glob("*-In*_Cu.g*"):
+                    path.unlink()
+                for version in versions:
+                    self.write_layers(version)
+                self.assert_layers(10)
+
+    def test_incomplete_current_export_does_not_mix_versions(self):
+        self.write_layers(8)
+        (self.gerber / "hellen1test-In1_Cu.g1").write_text("new layer 1")
+        result = self.copy_frame()
+        self.assertEqual(result.returncode, 2)
+        self.assertIn("Incomplete internal Gerber layer pair", result.stdout)
+
+    def test_cleanup_is_scoped_and_repeatable(self):
+        self.write_layers(8)
+        self.write_layers(10)
+        unrelated = self.gerber / "other-In1_Cu.g2"
+        unrelated.write_text("another board")
+        before = {p.name: p.read_bytes() for p in self.gerber.iterdir()}
+        result = self.run_script("cleanup_kicad_gerbers.py", self.gerber,
+                                 "hellen1test", "--dry-run")
+        self.assertEqual(result.returncode, 0, result.stderr)
+        self.assertEqual(before, {p.name: p.read_bytes() for p in self.gerber.iterdir()})
+        for _ in range(2):
+            result = self.run_script("cleanup_kicad_gerbers.py", self.gerber, "hellen1test")
+            self.assertEqual(result.returncode, 0, result.stderr)
+        for obsolete in ("hellen1test-In1_Cu.g2", "hellen1test-In2_Cu.g3"):
+            del before[obsolete]
+        self.assertEqual(before, {p.name: p.read_bytes() for p in self.gerber.iterdir()})
+        self.assert_layers(10)
+
+    def test_cleanup_preserves_legacy_only_export(self):
+        self.write_layers(8)
+        result = self.run_script("cleanup_kicad_gerbers.py", self.gerber, "hellen1test")
+        self.assertEqual(result.returncode, 0, result.stderr)
+        self.assert_layers(8)
+
+
+if __name__ == "__main__":
+    unittest.main()