Controller board: ESP32 + 2x StepStick carrier (v0.4), FluidNC config
- KiCad project generated by pcb/tools (design, route, schematic, fab outputs). - v0.4 fixes the v0.3 review findings: low-dropout 3.3 V regulator, OR'd 5 V supply, polyfuse, USB ESD protection, input clamps, ceramic decoupling at the drivers, A4988/DRV8825 jumper, ground stitching. DRC/ERC clean. - v0.3 (as ordered) kept in pcb/archive/v0.3. - FluidNC config.yaml for the board; rho hard limit on. Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
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ckochandClaude Opus 5.5 committed
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"""Load footprints and symbols from the installed KiCad libraries."""
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import math
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import os
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from sexpr import parse, find, findall, QStr
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KICAD = os.environ.get('KICAD_SHARE', '/snap/kicad/current/usr/share/kicad')
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FP_DIR = os.path.join(KICAD, 'footprints')
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SYM_DIR = os.path.join(KICAD, 'symbols')
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def load_footprint(lib_id, min_drill=None, min_ring=0.2, solid_thermal_pads=False):
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lib, name = lib_id.split(':', 1)
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path = os.path.join(FP_DIR, lib + '.pretty', name + '.kicad_mod')
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with open(path) as f:
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fp = parse(f.read())
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if solid_thermal_pads:
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_solidify_thermal_pads(fp)
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if min_drill:
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_enforce_min_drill(fp, min_drill, min_ring)
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return fp
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def _solidify_thermal_pads(fp):
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"""Remove plated holes that sit inside a cluster of same-numbered SMD pads (thermal vias in an
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exposed pad) and add one copper-only pad over the cluster, so the copper stays continuous under
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the solder-mask/paste windows but no hole is left in a pad. Fabs flag holes in pads (solder
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wicks into them) and charge for resin filling."""
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import copy
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pads = findall(fp, 'pad')
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by_num = {}
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for p in pads:
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by_num.setdefault(str(p[1]), []).append(p)
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for num, group in by_num.items():
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smd = [p for p in group if str(p[2]) == 'smd']
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tht = [p for p in group if str(p[2]) == 'thru_hole']
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if len(smd) < 2 or not tht:
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continue
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boxes = []
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for p in smd:
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at, size = find(p, 'at'), find(p, 'size')
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x, y, w, h = float(at[1]), float(at[2]), float(size[1]), float(size[2])
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boxes.append((x - w / 2, y - h / 2, x + w / 2, y + h / 2))
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x0, y0 = min(b[0] for b in boxes), min(b[1] for b in boxes)
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x1, y1 = max(b[2] for b in boxes), max(b[3] for b in boxes)
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inside = [p for p in tht if x0 - 0.5 <= float(find(p, 'at')[1]) <= x1 + 0.5
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and y0 - 0.5 <= float(find(p, 'at')[2]) <= y1 + 0.5]
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if not inside:
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continue
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for p in inside:
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fp.remove(p)
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solid = copy.deepcopy(smd[0])
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solid[:] = [v for v in solid if not (isinstance(v, list) and v and v[0] in ('uuid', 'roundrect_rratio'))]
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solid[3] = 'rect'
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at, size, layers = find(solid, 'at'), find(solid, 'size'), find(solid, 'layers')
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at[1:] = [f'{(x0 + x1) / 2:g}', f'{(y0 + y1) / 2:g}']
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size[1:] = [f'{x1 - x0:g}', f'{y1 - y0:g}']
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layers[1:] = [QStr('F.Cu')]
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fp.insert(fp.index(smd[0]), solid)
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def _enforce_min_drill(fp, min_drill, min_ring):
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"""Grow round plated holes below min_drill (and their copper ring) so the board fits the fab's process."""
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for p in findall(fp, 'pad'):
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if str(p[2]) != 'thru_hole':
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continue
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drill = find(p, 'drill')
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if not drill or len(drill) < 2 or isinstance(drill[1], list) or str(drill[1]) == 'oval':
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continue
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if float(drill[1]) >= min_drill - 1e-9:
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continue
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drill[1] = f'{min_drill:g}'
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size = find(p, 'size')
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need = min_drill + 2 * min_ring
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for i in (1, 2):
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if float(size[i]) < need:
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size[i] = f'{need:g}'
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def fp_pads(fp):
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"""Pads as dicts in footprint-local coords (KiCad: y down)."""
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pads = []
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for p in findall(fp, 'pad'):
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num = str(p[1])
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kind = p[2] # smd / thru_hole / np_thru_hole / connect
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shape = p[3]
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at = find(p, 'at')
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x, y = float(at[1]), float(at[2])
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rot = float(at[3]) if len(at) > 3 else 0.0
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size = find(p, 'size')
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w, h = float(size[1]), float(size[2])
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layers = [str(l) for l in find(p, 'layers')[1:]]
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drill = find(p, 'drill')
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d = None
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if drill:
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vals = [v for v in drill[1:] if not isinstance(v, list)]
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if vals and vals[0] == 'oval':
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d = (float(vals[1]), float(vals[2]) if len(vals) > 2 else float(vals[1]))
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elif vals:
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d = (float(vals[0]), float(vals[0]))
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pads.append(dict(num=num, kind=kind, shape=shape, x=x, y=y, rot=rot,
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w=w, h=h, layers=layers, drill=d, node=p))
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return pads
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def fp_courtyard(fp):
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"""Bounding box (x0,y0,x1,y1) of the front/back courtyard lines/rects."""
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xs, ys = [], []
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for kind in ('fp_line', 'fp_rect', 'fp_circle', 'fp_arc', 'fp_poly'):
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for g in findall(fp, kind):
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layer = find(g, 'layer')
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if not layer or 'CrtYd' not in str(layer[1]):
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continue
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for key in ('start', 'end', 'mid', 'center'):
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pt = find(g, key)
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if pt:
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xs.append(float(pt[1])); ys.append(float(pt[2]))
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pts = find(g, 'pts')
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if pts:
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for xy in findall(pts, 'xy'):
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xs.append(float(xy[1])); ys.append(float(xy[2]))
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if kind == 'fp_circle':
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c = find(g, 'center'); e = find(g, 'end')
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r = math.hypot(float(e[1]) - float(c[1]), float(e[2]) - float(c[2]))
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xs += [float(c[1]) - r, float(c[1]) + r]
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ys += [float(c[2]) - r, float(c[2]) + r]
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if not xs:
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return None
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return (min(xs), min(ys), max(xs), max(ys))
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_symlib_cache = {}
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def load_symbol(lib_id):
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"""Return the symbol definition list (with 'extends' resolved)."""
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lib, name = lib_id.split(':', 1)
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if lib not in _symlib_cache:
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with open(os.path.join(SYM_DIR, lib + '.kicad_sym')) as f:
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_symlib_cache[lib] = parse(f.read())
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root = _symlib_cache[lib]
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syms = {str(s[1]): s for s in findall(root, 'symbol')}
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s = syms[name]
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ext = find(s, 'extends')
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if ext:
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base = load_symbol(lib + ':' + str(ext[1]))
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# copy base, take name + properties from derived
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import copy
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merged = copy.deepcopy(base)
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merged[1] = QStr(name)
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# rename sub-units
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for sub in findall(merged, 'symbol'):
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sub[1] = QStr(str(sub[1]).replace(str(ext[1]), name, 1))
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# properties: inherited from the base, overridden/extended by the derived symbol
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base_props = findall(merged, 'property')
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merged = [x for x in merged if not (isinstance(x, list) and x and x[0] == 'property')]
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derived = {str(p[1]): p for p in findall(s, 'property')}
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props = []
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for p in base_props:
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props.append(derived.pop(str(p[1]), p))
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props += list(derived.values())
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# insert properties after the symbol-level flags
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idx = 2
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while idx < len(merged) and isinstance(merged[idx], list) and merged[idx][0] in ('pin_names', 'pin_numbers', 'exclude_from_sim', 'in_bom', 'on_board'):
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idx += 1
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merged = merged[:idx] + props + merged[idx:]
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return merged
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return s
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def sym_pins(sym):
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"""Pins (number, name, type, x, y, angle, length) in symbol coords (y up)."""
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pins = []
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for unit in findall(sym, 'symbol'):
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for p in findall(unit, 'pin'):
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at = find(p, 'at')
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length = float(find(p, 'length')[1])
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name = find(p, 'name')
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number = find(p, 'number')
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pins.append(dict(type=str(p[1]), style=str(p[2]),
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x=float(at[1]), y=float(at[2]), angle=float(at[3]) if len(at) > 3 else 0.0,
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length=length, name=str(name[1]), num=str(number[1]),
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hidden=('hide' in [str(v) for v in p if not isinstance(v, list)]),
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unit=str(unit[1])))
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return pins
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