Understanding filled areas inside the panelized board

[fiechr]

Usually, when I use filled copper areas, I make them a little bit larger than the edge cut line around the board, since the the copper will stay away from the the PCB border anyway, if the clearance attribute is set for the area (which is usually is).

If I want to use KiKit for panelization, it seems, I have to change that, since I get a copper overlap error when exporting the Gerber files. First, I've started putting them on the same line, but that doesn't really seem to solve the issue.

I guess the reason is, that the actual board outline is now made of -- in my case -- v-cuts that are not recognized by the program and therefore the clearance has no effect. As soon as the areas are refilled they become a lot bigger.

The upper image is basically exactly what I want, but in only stays that way, if I don't refill the copper areas.

Now I wonder what the best approach is to deal with that?

First idea would be to maybe DON'T refill the areas after panel creation or somehow "freeze/lock" it? But this feels wrong and unreliable.

Another idea is to reduce the size of the area inside the source PCB to the distance I want? This would be the next thing I would be trying to do.

But I wonder if there is already a function in KiKit that deals with this kind of issue?

Also, is there any way for accounting for the V-cut width itself without making two V-cuts with additional material in between or changing the source PCB?

[yaqwsx]

The intended way is to not touching the panel (and thus not refilling zones) after it is created. You should input boards with already filled zones. KiKit v1.1 will have a switch to refill all zones.

At the moment, there is no function of the UI to compensate for the width of the V-Cut (but it can be done via scripting).

[fiechr]

So basically, I can export the Gerber files only "manually" at the moment, because "kikit fab ..." will automatically run a DRC that gives me an error (in this case)?

$ kikit fab jlcpcb WS2812b_12piecesBar.panelized.kicad_pcb /tmp/jlcpcb
** Found 36 DRC violations: **
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 96.6000 mm): Zone [Board_6-GND] on F.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-+5V] on F.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
[zones_intersect]: Copper areas intersect Severity: error
  Local override
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
  @(103.0000 mm, 103.0000 mm): Zone [Board_6-GND] on B.Cu
DRC failed. See report above. No files produced

It seems areas with zero distance in between are considered as intersecting by the KiCAD/DRC (which I don't get, really) even if not refilled.

I guess to best ignore DRC results on the panelized board completely and just export it using the regular way?

[yaqwsx]

Would you mind sharing the source design and panel? KiKit should produce panels that pass DRC. I would like to inspect this.

Nevertheless, the fab command supports the --no-drc option.

[fiechr]

Would you mind sharing the source design and panel? KiKit should produce panels that pass DRC. I would like to inspect this.

Not at all!

WS2812b_12piecesBar.zip

This includes the source and KiKit configuration JSON file as well, as the panelized file created with

kikit panelize -p kikit-panelize.json WS2812b_12piecesBar.kicad_pcb WS2812b_12piecesBar.panelized.kicad_pcb

[yaqwsx]

This is a DRC check I wasn't aware of. I have to think about how to resolve it properly and map it to KiCAD.

[fiechr]

Thank you for your work! :-)

As a workaround for now, I have offset the outer borders of the copper fill areas inwards, by the amount of clearance set for the respective area (in my case all are 0.3 mm). Now filled areas aren't influenced by the Edge.Cut layer anymore.
This works with 0 DRC errors for the source and the panelized file and kikit fab also works without errors.