@tscircuit/copper-pour-solver 0.0.1 → 0.0.3

package/.github/CODEOWNERS

@@ -0,0 +1 @@
+* @seveibar @ShiboSoftwareDev

package/dist/index.d.ts

@@ -10,6 +10,7 @@ interface InputPourRegion {
     connectivityKey: string;
     padMargin: number;
     traceMargin: number;
+    boardEdgeMargin?: number;
 }
 interface BaseInputPad {
     padId: string;
@@ -52,6 +53,7 @@ declare const convertCircuitJsonToInputProblem: (circuitJson: AnyCircuitElement[
     pour_connectivity_key: string;
     pad_margin: number;
     trace_margin: number;
+    boardEdgeMargin?: number;
 }) => InputProblem;
 
 export { type BaseInputPad, CopperPourPipelineSolver, type InputCircularPad, type InputPad, type InputPourRegion, type InputProblem, type InputRectPad, type InputTracePad, type PipelineOutput, convertCircuitJsonToInputProblem };

package/dist/index.js

@@ -4,18 +4,29 @@ import { BasePipelineSolver } from "@tscircuit/solver-utils";
 // lib/solvers/copper-pour/get-board-polygon.ts
 import Flatten from "@flatten-js/core";
 var getBoardPolygon = (region) => {
+  const boardEdgeMargin = region.boardEdgeMargin ?? 0;
   if (region.outline && region.outline.length > 0) {
-    return new Flatten.Polygon(
+    const polygon = new Flatten.Polygon(
       region.outline.map((p) => Flatten.point(p.x, p.y))
     );
+    return polygon;
   }
   const { bounds } = region;
+  const newBounds = {
+    minX: bounds.minX + boardEdgeMargin,
+    minY: bounds.minY + boardEdgeMargin,
+    maxX: bounds.maxX - boardEdgeMargin,
+    maxY: bounds.maxY - boardEdgeMargin
+  };
+  if (newBounds.minX >= newBounds.maxX || newBounds.minY >= newBounds.maxY) {
+    return new Flatten.Polygon();
+  }
   return new Flatten.Polygon(
     new Flatten.Box(
-      bounds.minX,
-      bounds.minY,
-      bounds.maxX,
-      bounds.maxY
+      newBounds.minX,
+      newBounds.minY,
+      newBounds.maxX,
+      newBounds.maxY
     ).toPoints()
   );
 };
@@ -46,9 +57,67 @@ var circleToPolygon = (circle, numSegments = 32) => {
 var isRectPad = (pad) => pad.shape === "rect";
 var isTracePad = (pad) => pad.shape === "trace";
 var isCircularPad = (pad) => pad.shape === "circle";
-var processObstaclesForPour = (pads, pourConnectivityKey, margins) => {
+var processObstaclesForPour = (pads, pourConnectivityKey, margins, boardOutline) => {
   const polygonsToSubtract = [];
-  const { padMargin, traceMargin } = margins;
+  const { padMargin, traceMargin, boardEdgeMargin } = margins;
+  if (boardOutline && boardOutline.length > 0 && boardEdgeMargin && boardEdgeMargin > 0) {
+    const boardPoly = new Flatten3.Polygon(
+      boardOutline.map((p) => Flatten3.point(p.x, p.y))
+    );
+    if (boardPoly.area() < 0) {
+      boardPoly.reverse();
+    }
+    const vertices = boardPoly.vertices;
+    for (let i = 0; i < vertices.length; i++) {
+      const p1 = vertices[i === 0 ? vertices.length - 1 : i - 1];
+      const p2 = vertices[i];
+      const p3 = vertices[(i + 1) % vertices.length];
+      if (!p1 || !p2 || !p3) continue;
+      const v1 = new Flatten3.Vector(p1, p2);
+      const v2 = new Flatten3.Vector(p2, p3);
+      const crossProduct = v1.cross(v2);
+      const circle = new Flatten3.Circle(p2, boardEdgeMargin);
+      polygonsToSubtract.push(circleToPolygon(circle));
+      if (crossProduct < 0) {
+        const box = new Flatten3.Box(
+          p2.x - boardEdgeMargin,
+          p2.y - boardEdgeMargin,
+          p2.x + boardEdgeMargin,
+          p2.y + boardEdgeMargin
+        );
+        polygonsToSubtract.push(new Flatten3.Polygon(box.toPoints()));
+      }
+    }
+    for (let i = 0; i < vertices.length; i++) {
+      const p1 = vertices[i];
+      const p2 = vertices[(i + 1) % vertices.length];
+      if (!p1 || !p2) continue;
+      const segmentLength = Math.hypot(p1.x - p2.x, p1.y - p2.y);
+      if (segmentLength === 0) continue;
+      const enlargedWidth = boardEdgeMargin * 2;
+      const centerX = (p1.x + p2.x) / 2;
+      const centerY = (p1.y + p2.y) / 2;
+      const rotationDeg = Math.atan2(p2.y - p1.y, p2.x - p1.x) * 180 / Math.PI;
+      const w2 = segmentLength / 2;
+      const h2 = enlargedWidth / 2;
+      const angleRad = rotationDeg * Math.PI / 180;
+      const cosAngle = Math.cos(angleRad);
+      const sinAngle = Math.sin(angleRad);
+      const corners = [
+        { x: -w2, y: -h2 },
+        { x: w2, y: -h2 },
+        { x: w2, y: h2 },
+        { x: -w2, y: h2 }
+      ];
+      const rotatedCorners = corners.map((p) => ({
+        x: centerX + p.x * cosAngle - p.y * sinAngle,
+        y: centerY + p.x * sinAngle + p.y * cosAngle
+      }));
+      polygonsToSubtract.push(
+        new Flatten3.Polygon(rotatedCorners.map((p) => Flatten3.point(p.x, p.y)))
+      );
+    }
+  }
   for (const pad of pads) {
     const isOnNet = pad.connectivityKey === pourConnectivityKey;
     if (isOnNet) {
@@ -184,15 +253,26 @@ var CopperPourPipelineSolver = class extends BasePipelineSolver {
         region.connectivityKey,
         {
           padMargin: region.padMargin,
-          traceMargin: region.traceMargin
-        }
+          traceMargin: region.traceMargin,
+          boardEdgeMargin: region.boardEdgeMargin
+        },
+        region.outline
       );
       let pourPolygons = boardPolygon;
       for (const poly of polygonsToSubtract) {
-        pourPolygons = Flatten5.BooleanOperations.subtract(
-          pourPolygons,
-          poly
-        );
+        const currentPolys = Array.isArray(pourPolygons) ? pourPolygons : [pourPolygons];
+        const nextPolys = [];
+        for (const p of currentPolys) {
+          const result = Flatten5.BooleanOperations.subtract(p, poly);
+          if (result) {
+            if (Array.isArray(result)) {
+              nextPolys.push(...result.filter((r) => !r.isEmpty()));
+            } else {
+              if (!result.isEmpty()) nextPolys.push(result);
+            }
+          }
+        }
+        pourPolygons = nextPolys;
       }
       const new_breps = generateBRep(pourPolygons);
       brep_shapes.push(...new_breps);
@@ -354,7 +434,8 @@ var convertCircuitJsonToInputProblem = (circuitJson, options) => {
       outline: pcb_board.outline,
       connectivityKey: options.pour_connectivity_key,
       padMargin: options.pad_margin,
-      traceMargin: options.trace_margin
+      traceMargin: options.trace_margin,
+      boardEdgeMargin: options.boardEdgeMargin ?? 0
     }
   ];
   return {

package/lib/circuit-json/convert-circuit-json-to-input-problem.ts

@@ -26,6 +26,7 @@ export const convertCircuitJsonToInputProblem = (
     pour_connectivity_key: string
     pad_margin: number
     trace_margin: number
+    boardEdgeMargin?: number
   },
 ): InputProblem => {
   const source_ports = circuitJson.filter(
@@ -198,6 +199,7 @@ export const convertCircuitJsonToInputProblem = (
       connectivityKey: options.pour_connectivity_key,
       padMargin: options.pad_margin,
       traceMargin: options.trace_margin,
+      boardEdgeMargin: options.boardEdgeMargin ?? 0,
     },
   ]
 

package/lib/solvers/CopperPourPipelineSolver.ts

@@ -28,16 +28,29 @@ export class CopperPourPipelineSolver extends BasePipelineSolver<InputProblem> {
         {
           padMargin: region.padMargin,
           traceMargin: region.traceMargin,
+          boardEdgeMargin: region.boardEdgeMargin,
         },
+        region.outline,
       )
 
-      let pourPolygons: Flatten.Polygon = boardPolygon
+      let pourPolygons: Flatten.Polygon | Flatten.Polygon[] = boardPolygon
 
       for (const poly of polygonsToSubtract) {
-        pourPolygons = Flatten.BooleanOperations.subtract(
-          pourPolygons,
-          poly,
-        ) as Flatten.Polygon
+        const currentPolys = Array.isArray(pourPolygons)
+          ? pourPolygons
+          : [pourPolygons]
+        const nextPolys: Flatten.Polygon[] = []
+        for (const p of currentPolys) {
+          const result = Flatten.BooleanOperations.subtract(p, poly)
+          if (result) {
+            if (Array.isArray(result)) {
+              nextPolys.push(...result.filter((r) => !r.isEmpty()))
+            } else {
+              if (!result.isEmpty()) nextPolys.push(result)
+            }
+          }
+        }
+        pourPolygons = nextPolys
       }
 
       const new_breps = generateBRep(pourPolygons)

package/lib/solvers/copper-pour/get-board-polygon.ts

@@ -2,18 +2,33 @@ import type { InputPourRegion } from "lib/types"
 import Flatten from "@flatten-js/core"
 
 export const getBoardPolygon = (region: InputPourRegion): Flatten.Polygon => {
+  const boardEdgeMargin = region.boardEdgeMargin ?? 0
+
   if (region.outline && region.outline.length > 0) {
-    return new Flatten.Polygon(
+    const polygon = new Flatten.Polygon(
       region.outline.map((p) => Flatten.point(p.x, p.y)),
     )
+    return polygon
   }
+
   const { bounds } = region
+  const newBounds = {
+    minX: bounds.minX + boardEdgeMargin,
+    minY: bounds.minY + boardEdgeMargin,
+    maxX: bounds.maxX - boardEdgeMargin,
+    maxY: bounds.maxY - boardEdgeMargin,
+  }
+
+  if (newBounds.minX >= newBounds.maxX || newBounds.minY >= newBounds.maxY) {
+    return new Flatten.Polygon()
+  }
+
   return new Flatten.Polygon(
     new Flatten.Box(
-      bounds.minX,
-      bounds.minY,
-      bounds.maxX,
-      bounds.maxY,
+      newBounds.minX,
+      newBounds.minY,
+      newBounds.maxX,
+      newBounds.maxY,
     ).toPoints(),
   )
 }

package/lib/solvers/copper-pour/process-obstacles.ts

@@ -1,4 +1,5 @@
 import Flatten from "@flatten-js/core"
+import type { Point } from "@tscircuit/math-utils"
 import type {
   InputCircularPad,
   InputPad,
@@ -20,11 +21,93 @@ const isCircularPad = (pad: InputPad): pad is InputCircularPad =>
 export const processObstaclesForPour = (
   pads: InputPad[],
   pourConnectivityKey: string,
-  margins: { padMargin: number; traceMargin: number },
+  margins: { padMargin: number; traceMargin: number; boardEdgeMargin?: number },
+  boardOutline?: Point[],
 ): ProcessedObstacles => {
   const polygonsToSubtract: Flatten.Polygon[] = []
 
-  const { padMargin, traceMargin } = margins
+  const { padMargin, traceMargin, boardEdgeMargin } = margins
+
+  if (
+    boardOutline &&
+    boardOutline.length > 0 &&
+    boardEdgeMargin &&
+    boardEdgeMargin > 0
+  ) {
+    const boardPoly = new Flatten.Polygon(
+      boardOutline.map((p) => Flatten.point(p.x, p.y)),
+    )
+    if (boardPoly.area() < 0) {
+      boardPoly.reverse()
+    }
+    const vertices = boardPoly.vertices
+
+    // Add clearance shapes at vertices
+    for (let i = 0; i < vertices.length; i++) {
+      const p1 = vertices[i === 0 ? vertices.length - 1 : i - 1]
+      const p2 = vertices[i]
+      const p3 = vertices[(i + 1) % vertices.length]
+
+      if (!p1 || !p2 || !p3) continue
+
+      const v1 = new Flatten.Vector(p1, p2)
+      const v2 = new Flatten.Vector(p2, p3)
+      const crossProduct = v1.cross(v2)
+
+      const circle = new Flatten.Circle(p2, boardEdgeMargin)
+      polygonsToSubtract.push(circleToPolygon(circle))
+
+      if (crossProduct < 0) {
+        const box = new Flatten.Box(
+          p2.x - boardEdgeMargin,
+          p2.y - boardEdgeMargin,
+          p2.x + boardEdgeMargin,
+          p2.y + boardEdgeMargin,
+        )
+        polygonsToSubtract.push(new Flatten.Polygon(box.toPoints()))
+      }
+    }
+
+    // Add rectangles for each segment to create clearance along edges
+    for (let i = 0; i < vertices.length; i++) {
+      const p1 = vertices[i]
+      const p2 = vertices[(i + 1) % vertices.length]
+
+      if (!p1 || !p2) continue
+
+      const segmentLength = Math.hypot(p1.x - p2.x, p1.y - p2.y)
+      if (segmentLength === 0) continue
+
+      const enlargedWidth = boardEdgeMargin * 2
+
+      const centerX = (p1.x + p2.x) / 2
+      const centerY = (p1.y + p2.y) / 2
+      const rotationDeg = (Math.atan2(p2.y - p1.y, p2.x - p1.x) * 180) / Math.PI
+
+      const w2 = segmentLength / 2
+      const h2 = enlargedWidth / 2
+
+      const angleRad = (rotationDeg * Math.PI) / 180
+      const cosAngle = Math.cos(angleRad)
+      const sinAngle = Math.sin(angleRad)
+
+      const corners = [
+        { x: -w2, y: -h2 },
+        { x: w2, y: -h2 },
+        { x: w2, y: h2 },
+        { x: -w2, y: h2 },
+      ]
+
+      const rotatedCorners = corners.map((p) => ({
+        x: centerX + p.x * cosAngle - p.y * sinAngle,
+        y: centerY + p.x * sinAngle + p.y * cosAngle,
+      }))
+
+      polygonsToSubtract.push(
+        new Flatten.Polygon(rotatedCorners.map((p) => Flatten.point(p.x, p.y))),
+      )
+    }
+  }
 
   for (const pad of pads) {
     const isOnNet = pad.connectivityKey === pourConnectivityKey

package/lib/types.ts

@@ -9,6 +9,7 @@ export interface InputPourRegion {
   connectivityKey: string
   padMargin: number
   traceMargin: number
+  boardEdgeMargin?: number
 }
 
 export interface BaseInputPad {

package/package.json

@@ -1,15 +1,16 @@
 {
   "name": "@tscircuit/copper-pour-solver",
   "main": "dist/index.js",
-  "version": "0.0.1",
+  "version": "0.0.3",
   "scripts": {
     "format": "biome format . --write",
+    "format:check": "biome format .",
     "build": "tsup-node lib/index.ts --dts --format esm"
   },
   "type": "module",
   "devDependencies": {
     "@biomejs/biome": "^2.2.4",
-    "@flatten-js/core": "^1.6.6",
+    "@flatten-js/core": "^1.6.2",
     "@tscircuit/math-utils": "^0.0.25",
     "@tscircuit/solver-utils": "^0.0.3",
     "@types/bun": "latest",

package/tests/__snapshots__/circuit-7.snap.svg

@@ -0,0 +1 @@
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package/tests/__snapshots__/circuit-8.snap.svg

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