@tscircuit/fanout-solver 0.0.60 → 0.0.62

package/README.md

@@ -282,8 +282,8 @@ extents.
 
 ## Dataset 31 benchmark
 
-Run `./benchmark.sh` (or `bun run benchmark`) to benchmark **only the 12 AM62L
-directional cases** from
+Run `./benchmark.sh` (or `bun run benchmark`) to benchmark **all 24 dataset 31
+directional cases: 12 AM62L and 12 RK3308** from
 [`tscircuit/dataset-fanout31-am62l`](https://github.com/tscircuit/dataset-fanout31-am62l).
 The upstream revision is pinned in `scripts/generate-repro/package.json` and
 recorded in every report. Other datasets remain available for regression tests
@@ -293,14 +293,24 @@ and the debugger, but have no benchmark commands or workflows.
 ./benchmark.sh
 ./benchmark.sh --list
 ./benchmark.sh --sample 11-left-center
+./benchmark.sh --sample 13-rk3308-top-left-offset
 ./benchmark.sh --concurrency 8 --sample-timeout-seconds 300
 ```
 
 Before timing the solver, the benchmark renders the selected upstream TSX/core
 circuits and captures their exact fanout-solver constructor inputs into
-`benchmark-results/inputs/<sample-id>.json`. Each case retains all 135 AM62L
-connections, 573 pad obstacles, nine DDR buses, 102 plane drops, and the original
-clearance, differential-pair, and length-skew constraints. The timed workers run
+`benchmark-results/inputs/<sample-id>.json`. Each case retains its complete
+SoC fanout workload and the original clearance, differential-pair, and length-skew
+constraints:
+
+| SoC | Cases | Signal connections | Plane drops | Total connections | Pad obstacles |
+| --- | ---: | ---: | ---: | ---: | ---: |
+| AM62L | 12 | 33 | 102 | 135 | 573 |
+| RK3308 | 12 | 49 | 113 | 162 | 451 |
+
+Both families have nine DDR signal buses. The RK3308 samples use a 355-ball SoC
+and 96-ball DDR3L RAM, with the RAM placed on each side at three offsets.
+The timed workers run
 **this checkout's solver**, not the upstream package's released solver.
 To capture the inputs without solving, use `bun run generate:dataset31`.
 The optional `--dataset dataset31` flag is accepted for explicit CI invocation;
@@ -335,8 +345,10 @@ are committed so route changes can be reviewed in Git. A run replaces the select
 cases' snapshots and removes their stale SVGs if they no longer solve; filtered
 runs preserve unselected snapshots. JSON reports and captured inputs remain
 ignored. CI includes the SVGs in its benchmark artifacts.
-Compare reports with the same budgets to track progress. Solved means validated
-AM62L fanout, not RAM fanout or downstream inter-chip routing. Partial, error,
+Compare reports with the same dataset revision and budgets to track progress.
+A case is solved only when every SoC connection has validated fanout: all 135
+connections for AM62L or all 162 for RK3308. This covers the SoC fanout phase; RAM
+fanout and downstream inter-chip routing are separate phases. Partial, error,
 and timeout rows are benchmark results (exit 0); invalid CLI arguments or report
 I/O failures are command failures (nonzero exit).
 
@@ -344,7 +356,7 @@ I/O failures are command failures (nonzero exit).
 
 Once `.github/workflows/benchmark.yml` is on the default branch, a repository
 writer can comment **`/benchmark`** on an open PR. The workflow captures that
-PR's exact head SHA, runs all 12 dataset 31 samples on a **32-vCPU Blacksmith ARM**
+PR's exact head SHA, runs all 24 dataset 31 samples on a **32-vCPU Blacksmith ARM**
 runner, then updates a status comment with solve totals, per-sample results,
 and a link to the complete JSON/Markdown reports and captured inputs. The Actions
 UI also supports a manual run, optionally supplying an open PR number. No custom
@@ -510,8 +522,8 @@ bun run render:dataset
 bun run start
 ```
 
-The benchmark runs only the 12 dataset 31 AM62L cases and reports solve counts,
-validation, and timing. `bun run start` opens all regression
+The benchmark runs all 24 dataset 31 AM62L and RK3308 cases and reports solve
+counts, validation, and timing. `bun run start` opens all regression
 datasets in the standard tscircuit solver debugger. `bun run
 render:dataset` writes `graphics-debug` PNGs under one subdirectory per dataset,
 with a red shared boundary, gray component courtyards, and green fanout-exit

package/lib/fanout-solver.ts

@@ -23,6 +23,7 @@ import {
 import { matchBusPlanLengths } from "./match-bus-lengths"
 import {
   getComponentDogboneViaSiteCandidates,
+  getSingleDogboneViaSiteRepairs,
   matchComponentDogboneViaSites,
 } from "./match-component-dogbone-via-sites"
 import { connectionsShareElectricalNet } from "./net-identity"
@@ -467,6 +468,9 @@ function createInitialLayerAssignment(params: {
   escapeLayers: string[]
   escapeLayersByBusId: Readonly<Record<string, readonly string[]>>
   preferOrderedCoordinatedWindingLayers: boolean
+  traceWidth: number
+  viaDiameter: number
+  clearance: number
 }): Readonly<Record<string, string>> {
   const {
     buses,
@@ -513,10 +517,151 @@ function createInitialLayerAssignment(params: {
         preferOrderedCoordinatedWindingLayers &&
         busUsesCoordinatedWinding(bus)
       ) {
-        // Coordinated winding treats allowedLayers as an ordered preference.
-        // A global round-robin index can otherwise skip a bus's first choice
-        // just because a previous bus had a different set of legal layers.
-        assignment[bus.busId] = viaLayers[0]!
+        // Preserve caller preferences when boundary corridors are free. A
+        // centered or turning bus with a common target layer can occupy the
+        // same boundary band, so prefer another legal layer for a wide route.
+        const cornerSide = getCornerBandSide(bus.exitEdge, bus.preferredExit)
+        const getBoundaryCongestion = (layer: string): number => {
+          if (!bus.exitEdge || bus.connections.length < 8) return 0
+          const horizontalEdge =
+            bus.exitEdge === "left" || bus.exitEdge === "right"
+          const axis = horizontalEdge ? "y" : "x"
+          const minimum = horizontalEdge
+            ? bus.sharedBoundary.minY
+            : bus.sharedBoundary.minX
+          const maximum = horizontalEdge
+            ? bus.sharedBoundary.maxY
+            : bus.sharedBoundary.maxX
+          if (!cornerSide) {
+            const tracks = bus.connections.map((connection) => {
+              const target =
+                connection.exitTargetPoint ?? connection.targetPoint
+              return Math.max(minimum, Math.min(maximum, target[axis]))
+            })
+            const bandMinimum = Math.min(...tracks)
+            const bandMaximum = Math.max(...tracks)
+            const forwardAxis = horizontalEdge ? "x" : "y"
+            const sign =
+              bus.exitEdge === "right" || bus.exitEdge === "top" ? 1 : -1
+            const sourceNearEnd = Math.min(
+              ...bus.connections.map(
+                (connection) => sign * connection.sourcePoint[forwardAxis],
+              ),
+            )
+            const sourceMinimum = Math.min(
+              ...bus.connections.map(
+                (connection) => connection.sourcePoint[axis],
+              ),
+            )
+            const sourceMaximum = Math.max(
+              ...bus.connections.map(
+                (connection) => connection.sourcePoint[axis],
+              ),
+            )
+            return buses.reduce((count, other) => {
+              const otherCorner = getCornerBandSide(
+                other.exitEdge,
+                other.preferredExit,
+              )
+              if (
+                other === bus ||
+                other.termination.type !== "boundary" ||
+                other.componentId !== bus.componentId ||
+                other.exitEdge !== bus.exitEdge ||
+                !otherCorner ||
+                getCommonExplicitExitTargetLayer(other) !== layer
+              )
+                return count
+              const center =
+                minimum +
+                (maximum - minimum) * (otherCorner === "minimum" ? 0.25 : 0.75)
+              const halfWidth =
+                ((Math.max(
+                  other.connections.length,
+                  other.cornerBandConnectionCount ?? 0,
+                ) -
+                  1) *
+                  Math.max(
+                    params.traceWidth + params.clearance,
+                    params.viaDiameter + params.clearance,
+                  )) /
+                2
+              const margin = params.traceWidth + params.clearance
+              const overlapsBoundaryBand =
+                bandMaximum + margin >= center - halfWidth &&
+                bandMinimum - margin <= center + halfWidth
+              // A turning bus behind this source field must also pass its lanes
+              // on the way to the edge, even when its final band is elsewhere.
+              const crossesSourceField =
+                Math.max(
+                  ...other.connections.map(
+                    (connection) => sign * connection.sourcePoint[forwardAxis],
+                  ),
+                ) <
+                  sourceNearEnd - 1e-9 &&
+                Math.min(
+                  ...other.connections.map(
+                    (connection) => connection.sourcePoint[axis],
+                  ),
+                ) <=
+                  sourceMaximum + margin &&
+                Math.max(
+                  ...other.connections.map(
+                    (connection) => connection.sourcePoint[axis],
+                  ),
+                ) >=
+                  sourceMinimum - margin
+              return (
+                count +
+                (overlapsBoundaryBand || crossesSourceField
+                  ? other.connections.length
+                  : 0)
+              )
+            }, 0)
+          }
+          const bandCenter =
+            minimum +
+            (maximum - minimum) * (cornerSide === "minimum" ? 0.25 : 0.75)
+          const pitch = Math.max(
+            params.traceWidth + params.clearance,
+            params.viaDiameter + params.clearance,
+          )
+          const bandHalfWidth =
+            ((Math.max(
+              bus.connections.length,
+              bus.cornerBandConnectionCount ?? 0,
+            ) -
+              1) *
+              pitch) /
+            2
+          return buses.reduce((count, other) => {
+            if (
+              other === bus ||
+              other.termination.type !== "boundary" ||
+              other.componentId !== bus.componentId ||
+              other.exitEdge !== bus.exitEdge ||
+              getCornerBandSide(other.exitEdge, other.preferredExit) ||
+              getCommonExplicitExitTargetLayer(other) !== layer
+            )
+              return count
+            return (
+              count +
+              other.connections.filter((connection) => {
+                const target =
+                  connection.exitTargetPoint ?? connection.targetPoint
+                const track = Math.max(minimum, Math.min(maximum, target[axis]))
+                return (
+                  Math.abs(track - bandCenter) <=
+                  bandHalfWidth + params.traceWidth + params.clearance
+                )
+              }).length
+            )
+          }, 0)
+        }
+        assignment[bus.busId] = viaLayers.toSorted(
+          (first, second) =>
+            getBoundaryCongestion(first) - getBoundaryCongestion(second),
+        )[0]!
         continue
       }
       const componentDirections = directionsByComponent.get(bus.componentId)!
@@ -1046,6 +1191,9 @@ export class FanoutSolver extends BaseSolver {
           buses: this.preparedBuses,
           escapeLayers: this.config.escapeLayers,
           escapeLayersByBusId: this.escapeLayersByBusId,
+          traceWidth: this.config.traceWidth,
+          viaDiameter: this.config.viaDiameter,
+          clearance: this.config.clearance,
           preferOrderedCoordinatedWindingLayers:
             this.config.densePlaneReservationBusIds.length > 0 ||
             this.config.denseUnrestrictedPlaneRoutingBusIds.length > 0 ||
@@ -1486,6 +1634,64 @@ export class FanoutSolver extends BaseSolver {
     const wideBoundaryBuses = unsortedBoundaryBuses.filter(
       (bus) => bus.connections.length >= 8,
     )
+    // A single-layer turning bus beside the end of a centered source field
+    // has fewer escape choices than a corner bus farther behind it. Reserve
+    // that turning channel before the farther bus fences its local via sites.
+    const adjacentCenteredFieldByTurningBus = new Map<
+      PreparedBus,
+      PreparedBus
+    >()
+    if (usePadAlignedDenseRouting && !configuredDensePlaneRouting) {
+      for (const bus of wideBoundaryBuses) {
+        if (
+          !getCornerBandSide(bus.exitEdge, bus.preferredExit) ||
+          new Set(bus.routableEscapeLayers ?? bus.allowedLayers ?? []).size !==
+            1
+        )
+          continue
+        const axis =
+          bus.direction === "up" || bus.direction === "down" ? "y" : "x"
+        const track = axis === "x" ? "y" : "x"
+        const sign =
+          bus.direction === "up" || bus.direction === "right" ? 1 : -1
+        const forwardEnd = Math.max(
+          ...bus.connections.map((c) => sign * c.sourcePoint[axis]),
+        )
+        const minTrack = Math.min(
+          ...bus.connections.map((c) => c.sourcePoint[track]),
+        )
+        const maxTrack = Math.max(
+          ...bus.connections.map((c) => c.sourcePoint[track]),
+        )
+        const pitch = axis === "x" ? bus.pitchX : bus.pitchY
+        const field = wideBoundaryBuses.find((candidate) => {
+          if (
+            candidate === bus ||
+            candidate.componentId !== bus.componentId ||
+            candidate.exitEdge !== bus.exitEdge ||
+            getCornerBandSide(candidate.exitEdge, candidate.preferredExit)
+          )
+            return false
+          const nearEnd = Math.min(
+            ...candidate.connections.map((c) => sign * c.sourcePoint[axis]),
+          )
+          const gap = nearEnd - forwardEnd
+          return (
+            gap >= -1e-9 &&
+            gap <= pitch + 1e-9 &&
+            Math.min(
+              ...candidate.connections.map((c) => c.sourcePoint[track]),
+            ) <=
+              maxTrack + 1e-9 &&
+            Math.max(
+              ...candidate.connections.map((c) => c.sourcePoint[track]),
+            ) >=
+              minTrack - 1e-9
+          )
+        })
+        if (field) adjacentCenteredFieldByTurningBus.set(bus, field)
+      }
+    }
     const hasThreeWideBoundaryBuses =
       useConfiguredDensePlaneRouting && wideBoundaryBuses.length === 3
     const getBoundaryTargetSpan = (bus: PreparedBus) => {
@@ -2189,13 +2395,44 @@ export class FanoutSolver extends BaseSolver {
             bus,
           ]),
       ]
+      for (const [bus] of adjacentCenteredFieldByTurningBus) {
+        const axis =
+          bus.direction === "up" || bus.direction === "down" ? "y" : "x"
+        const sign =
+          bus.direction === "up" || bus.direction === "right" ? 1 : -1
+        const backwardEnd = Math.min(
+          ...bus.connections.map(
+            (connection) => sign * connection.sourcePoint[axis],
+          ),
+        )
+        const index = denseBoundaryBusesInRoutingOrder.indexOf(bus)
+        const earlierCornerIndex = denseBoundaryBusesInRoutingOrder.findIndex(
+          (candidate) =>
+            candidate !== bus &&
+            candidate.connections.length >= 8 &&
+            candidate.componentId === bus.componentId &&
+            candidate.direction === bus.direction &&
+            Math.max(
+              ...candidate.connections.map(
+                (connection) => sign * connection.sourcePoint[axis],
+              ),
+            ) <=
+              backwardEnd + 1e-9 &&
+            candidate.exitEdge === bus.exitEdge &&
+            getCornerBandSide(candidate.exitEdge, candidate.preferredExit) ===
+              getCornerBandSide(bus.exitEdge, bus.preferredExit),
+        )
+        if (earlierCornerIndex >= 0 && earlierCornerIndex < index) {
+          denseBoundaryBusesInRoutingOrder.splice(index, 1)
+          denseBoundaryBusesInRoutingOrder.splice(earlierCornerIndex, 0, bus)
+        }
+      }
       const areAdjacentInvertedNarrowBuses = (
         first: PreparedBus,
         second: PreparedBus,
       ): boolean => {
         if (
           !usePadAlignedDenseRouting ||
-          useConfiguredDensePlaneRouting ||
           first.componentId !== second.componentId ||
           first.exitEdge !== second.exitEdge ||
           first.direction !== second.direction ||
@@ -2259,7 +2496,7 @@ export class FanoutSolver extends BaseSolver {
       // turning pair instead leaves its adjacent singleton room to escape
       // before searching for an outside-package via.
       const centeredPairPromotionGroups = new Set<string>()
-      for (const singleton of multiLayerLeadingSingletonBuses) {
+      for (const singleton of leadingWideSingletonBuses) {
         if (getCornerBandSide(singleton.exitEdge, singleton.preferredExit))
           continue
         for (const pair of boundaryBuses) {
@@ -2300,6 +2537,25 @@ export class FanoutSolver extends BaseSolver {
           }
         }
       }
+      for (const field of adjacentCenteredFieldByTurningBus.values()) {
+        for (const pair of boundaryBuses) {
+          if (
+            pair.connections.length !== 2 ||
+            getContainingWideSourceField(pair) !== field
+          )
+            continue
+          for (const singleton of singletonBoundaryBuses) {
+            if (!areAdjacentInvertedNarrowBuses(singleton, pair)) continue
+            const pairIndex = denseBoundaryBusesInRoutingOrder.indexOf(pair)
+            const singletonIndex =
+              denseBoundaryBusesInRoutingOrder.indexOf(singleton)
+            if (singletonIndex > pairIndex) {
+              denseBoundaryBusesInRoutingOrder.splice(singletonIndex, 1)
+              denseBoundaryBusesInRoutingOrder.splice(pairIndex, 0, singleton)
+            }
+          }
+        }
+      }
       let fixedViaPointsByConnectionIndex: ReadonlyMap<
         number,
         { x: number; y: number }
@@ -2447,7 +2703,7 @@ export class FanoutSolver extends BaseSolver {
           useConfiguredDensePlaneRouting &&
           singleLayerBus !== bus &&
           !embeddedNarrowBusAlreadyRouted
-        let usedSoftPlaneRepair = false
+        let usedRepairedViaSites = false
         let busPlans = (yield* routeAlternatives(
           preferSingleLayerWinding
             ? { ...routeParams, bus: singleLayerBus }
@@ -2554,24 +2810,134 @@ export class FanoutSolver extends BaseSolver {
             }
           }
         }
-        // Once wide-bus copper constrains the field, retry a blocked wide bus
-        // with provisional plane sites as search costs. Future boundary sites
-        // remain fixed, and a complete joint rematch must validate the repair.
+        // A first turning bus can be fenced by one diagonal site even though
+        // every provisional dogbone is individually legal. Try moving one of
+        // its own sites while retaining all other through-via reservations.
+        // Keep this bounded repair ahead of the broader free-site search.
         if (
           !busPlans &&
+          useAdaptiveDensePlaneRouting &&
           bus.connections.length >= 8 &&
-          boundaryBuses.some(
-            (candidate) =>
-              candidate.connections.length >= 8 &&
-              matchedPlans.some((plan) => plan.busId === candidate.busId),
+          getCornerBandSide(bus.exitEdge, bus.preferredExit) &&
+          new Set(bus.routableEscapeLayers ?? bus.allowedLayers ?? []).size ===
+            1 &&
+          !matchedPlans.some((plan) =>
+            wideBoundaryBuses.some(
+              (candidate) => candidate.busId === plan.busId,
+            ),
           )
+        ) {
+          const reservedVias = getReservedVias(bus)
+          const siteRepairs = getSingleDogboneViaSiteRepairs(
+            bus,
+            {
+              viaDiameter: this.config.viaDiameter,
+              viaHoleDiameter: this.config.viaHoleDiameter,
+              traceWidth: this.config.traceWidth,
+              clearance: this.config.clearance,
+              additionalObstacles: this.routingSrj.obstacles,
+              blockingSegments: [
+                ...matchedPlans.flatMap((plan) =>
+                  plan.segments.map((segment) => ({
+                    connectionIndex: plan.connectionIndex,
+                    segment,
+                  })),
+                ),
+                ...reservedVias.flatMap((reserved) =>
+                  reserved.sourceEscapeSegment
+                    ? [
+                        {
+                          connectionIndex: -1,
+                          segment: reserved.sourceEscapeSegment,
+                        },
+                      ]
+                    : [],
+                ),
+              ],
+              blockingVias: [
+                ...matchedPlans.flatMap((plan) =>
+                  plan.via
+                    ? [{ connectionIndex: plan.connectionIndex, ...plan.via }]
+                    : [],
+                ),
+                ...reservedVias.map((reserved) => ({
+                  connectionIndex: -1,
+                  ...reserved.via,
+                })),
+              ],
+            },
+            fixedViaPointsByConnectionIndex,
+          )
+          for (const replacementPoints of siteRepairs) {
+            const replacementPlans = (yield* routeAlternatives(
+              {
+                ...routeParams,
+                fixedViaPointsByConnectionIndex: replacementPoints,
+                reservedVias,
+                fixedViaFallbackRouteOrderAttempts: 1,
+              },
+              1,
+            ))[0]
+            if (!replacementPlans) continue
+            busPlans = replacementPlans
+            fixedViaPointsByConnectionIndex = replacementPoints
+            usedRepairedViaSites = true
+            break
+          }
+        }
+        // Fixed dogbones can close a turning bus's own escape channel. Retry
+        // local sites while retaining every other connection's reservations.
+        if (
+          !busPlans &&
+          useAdaptiveDensePlaneRouting &&
+          bus.connections.length >= 8 &&
+          getCornerBandSide(bus.exitEdge, bus.preferredExit)
+        ) {
+          busPlans = (yield* routeAlternatives(
+            {
+              ...routeParams,
+              fixedViaPointsByConnectionIndex: undefined,
+              reservedVias: getReservedVias(bus),
+            },
+            1,
+          ))[0]
+          if (busPlans) {
+            usedRepairedViaSites = true
+            fixedViaPointsByConnectionIndex = new Map([
+              ...fixedViaPointsByConnectionIndex,
+              ...busPlans
+                .filter((plan) => plan.via)
+                .map(
+                  (plan) => [plan.connectionIndex, plan.via!.center] as const,
+                ),
+            ])
+          }
+          debugDense("local-sites", bus.busId, busPlans?.length ?? "failed")
+        }
+        // Retry a blocked wide bus with provisional plane sites as search
+        // costs. A turning bus beside a centered field may also need that
+        // neighboring field's uncommitted sites to move. Keep every committed
+        // route and narrow reservation hard, then require a complete rematch.
+        if (
+          !busPlans &&
+          bus.connections.length >= 8 &&
+          (adjacentCenteredFieldByTurningBus.has(bus) ||
+            boundaryBuses.some(
+              (candidate) =>
+                candidate.connections.length >= 8 &&
+                matchedPlans.some((plan) => plan.busId === candidate.busId),
+            ))
         ) {
           const committedNames = new Set(
             matchedPlans.map((plan) => plan.connectionName),
           )
-          const futurePlaneNames = new Set(
+          const provisionalReservationNames = new Set(
             this.preparedBuses
-              .filter((candidate) => candidate.termination.type === "plane")
+              .filter(
+                (candidate) =>
+                  candidate.termination.type === "plane" ||
+                  candidate === adjacentCenteredFieldByTurningBus.get(bus),
+              )
               .flatMap((candidate) =>
                 candidate.connections.map(
                   (connection) => connection.connection.name,
@@ -2584,10 +2950,11 @@ export class FanoutSolver extends BaseSolver {
               ...routeParams,
               fixedViaPointsByConnectionIndex: undefined,
               reservedVias: routeParams.reservedVias.filter(
-                (reserved) => !futurePlaneNames.has(reserved.connectionName),
+                (reserved) =>
+                  !provisionalReservationNames.has(reserved.connectionName),
               ),
               softReservedVias: routeParams.reservedVias.filter((reserved) =>
-                futurePlaneNames.has(reserved.connectionName),
+                provisionalReservationNames.has(reserved.connectionName),
               ),
             },
             1,
@@ -2630,7 +2997,7 @@ export class FanoutSolver extends BaseSolver {
             if (rematchedPoints) {
               busPlans = freePlans
               fixedViaPointsByConnectionIndex = rematchedPoints
-              usedSoftPlaneRepair = true
+              usedRepairedViaSites = true
             }
           }
         }
@@ -2647,12 +3014,12 @@ export class FanoutSolver extends BaseSolver {
           // Only pay for additional A* variants when the first topology is so
           // skewed that compact meanders are unlikely to absorb the deficit.
           // This keeps already-near-matched buses on the single-attempt path.
-          // Keep the jointly rematched repair: routeParams still carries the
+          // Keep repaired via sites: routeParams still carries the
           // earlier provisional sites and cannot safely replace its geometry.
           if (
             needsRouteDiversity &&
             !matchLengthsAfterPlanes &&
-            !usedSoftPlaneRepair
+            !usedRepairedViaSites
           ) {
             busPlans = (yield* routeAlternatives(routeParams, 3)).toSorted(
               (first, second) => {

package/lib/match-bus-lengths.ts

@@ -338,9 +338,33 @@ function replacementCopperIsSelfClear(params: {
       ) {
         continue
       }
+      const viaClearance = via.diameter / 2 + replacement.width / 2 + clearance
+      // An off-grid via can join this run through a short, connected stub.
+      // Preserve that existing connection while rejecting later approaches.
+      const connectsThroughShortStub = (direction: -1 | 1): boolean => {
+        let point = direction === -1 ? replacement.start : replacement.end
+        let pathDistance = 0
+        for (
+          let index = replacementIndex + direction;
+          index >= 0 && index < segments.length;
+          index += direction
+        ) {
+          const segment = segments[index]!
+          if (segment.layer !== replacement.layer) return false
+          const connectedEnd = direction === -1 ? segment.end : segment.start
+          if (!pointsMatch(point, connectedEnd)) return false
+          pathDistance += distance(segment.start, segment.end)
+          if (pathDistance > viaClearance + EPSILON) return false
+          point = direction === -1 ? segment.start : segment.end
+          if (pointsMatch(point, via.center)) return true
+        }
+        return false
+      }
       if (
         distancePointToSegment(via.center, replacement.start, replacement.end) <
-        via.diameter / 2 + replacement.width / 2 + clearance - EPSILON
+          viaClearance - EPSILON &&
+        !connectsThroughShortStub(-1) &&
+        !connectsThroughShortStub(1)
       ) {
         return false
       }

package/lib/match-component-dogbone-via-sites.ts

@@ -782,3 +782,30 @@ export function getComponentDogboneViaSiteCandidates(
     ),
   )
 }
+
+/** Try one adjacent site change without releasing any other fixed via. */
+export function* getSingleDogboneViaSiteRepairs(
+  bus: PreparedBus,
+  rules: DogboneViaSiteGeometryRules,
+  fixedViaPointsByConnectionIndex: ReadonlyMap<number, Point2D>,
+): Generator<ReadonlyMap<number, Point2D>, void, unknown> {
+  const sites = getComponentDogboneViaSiteCandidates([bus], rules)
+  let remainingAttempts = 24
+  for (const connection of bus.connections.toReversed()) {
+    const original = fixedViaPointsByConnectionIndex.get(
+      connection.connectionIndex,
+    )
+    if (!original) continue
+    for (const candidate of sites) {
+      if (
+        candidate.connectionIndex !== connection.connectionIndex ||
+        distance(candidate.point, original) <= EPSILON
+      )
+        continue
+      if (remainingAttempts-- <= 0) return
+      const replacement = new Map(fixedViaPointsByConnectionIndex)
+      replacement.set(connection.connectionIndex, candidate.point)
+      yield replacement
+    }
+  }
+}

package/lib/route-bus.ts

@@ -165,6 +165,7 @@ function getWindingTargetOrders(params: {
 }): {
   orders: PreparedConnection[][]
   legacyOrder: PreparedConnection[]
+  ordinaryOrderCount: number
 } {
   const { bus, boundaryDirection, layerNames, targetLayer } = params
   const getTargetLayer = (candidate: PreparedConnection): string =>
@@ -268,6 +269,41 @@ function getWindingTargetOrders(params: {
   // but do not let sub-nanometer noise between unrelated layer bands choose
   // the primary topology.
   candidateOrders.push(legacyOrderedConnections)
+  const ordinaryOrderCount = new Set(
+    candidateOrders.map((order) =>
+      order.map((candidate) => candidate.connectionIndex).join(","),
+    ),
+  ).size
+  // Preserve each original layer's lane order while exploring other legal
+  // interleavings. Keep this bounded for buses with many source layers.
+  if (
+    !getCornerSide(bus) &&
+    bus.connections.length <= 8 &&
+    orderedLayers.length > 1
+  ) {
+    const layerSequences = orderedLayers.map((layer) =>
+      connectionsByLayer.get(layer)!.toSorted(compareWithinLayer),
+    )
+    const offsets = layerSequences.map(() => 0)
+    const current: PreparedConnection[] = []
+    const append = (): void => {
+      if (candidateOrders.length >= 128) return
+      if (current.length === bus.connections.length) {
+        candidateOrders.push([...current])
+        return
+      }
+      for (let layer = 0; layer < layerSequences.length; layer++) {
+        const next = layerSequences[layer]![offsets[layer]!]
+        if (!next) continue
+        offsets[layer]++
+        current.push(next)
+        append()
+        current.pop()
+        offsets[layer]--
+      }
+    }
+    append()
+  }
   const seenOrders = new Set<string>()
   const orders = candidateOrders.filter((order) => {
     const key = order.map((candidate) => candidate.connectionIndex).join(",")
@@ -275,7 +311,7 @@ function getWindingTargetOrders(params: {
     seenOrders.add(key)
     return true
   })
-  return { orders, legacyOrder: legacyOrderedConnections }
+  return { orders, legacyOrder: legacyOrderedConnections, ordinaryOrderCount }
 }
 
 function getWindingTargetRank(params: {
@@ -318,6 +354,7 @@ function getDistributedBoundaryTargetTracks(params: {
   boundaryDirection: FanoutDirection
   traceWidth: number
   clearance: number
+  allowLayerInterleaving?: boolean
 }): number[] | undefined {
   const { bus, boundaryDirection, traceWidth, clearance } = params
   if (getCornerSide(bus) || !busUsesCoordinatedWindingChannel(bus))
@@ -352,6 +389,7 @@ function getDistributedBoundaryTargetTracks(params: {
     .toSorted((a, b) => a - b)
   const pitch = traceWidth + clearance
   if (
+    !params.allowLayerInterleaving &&
     tracks.every(
       (track, index) =>
         index === 0 || track - tracks[index - 1]! >= pitch - 1e-9,
@@ -396,6 +434,7 @@ export function getBoundaryTargetTrack(params: {
   layerNames?: readonly string[]
   targetLayer?: string
   windingOrderIndex?: number
+  allowLayerInterleaving?: boolean
 }): number {
   const requestedTrack = getPerpendicularAxis(
     params.connection.exitTargetPoint ?? params.connection.targetPoint,
@@ -2708,23 +2747,30 @@ export function* routeBusAlternativesSteps(
       windingOrderIndex?: number
       preferTargetDirectedLaneBias?: boolean
       localDogboneRepair?: boolean
+      reserveTerminalExitPoints?: boolean
+      cornerExitLaneOffset?: number
+      allowLayerInterleaving?: boolean
     }
     const maximumThroughAllRouteOrderAttempts = 24
-    const windingTargetOrderCount =
+    const usesDistributedWindingTargets = Boolean(
       cornerSide ||
-      getDistributedBoundaryTargetTracks({
-        bus,
-        boundaryDirection,
-        traceWidth,
-        clearance,
-      })
-        ? getWindingTargetOrders({
-            bus,
-            boundaryDirection,
-            layerNames,
-            targetLayer,
-          }).orders.length
-        : 1
+        getDistributedBoundaryTargetTracks({
+          bus,
+          boundaryDirection,
+          traceWidth,
+          clearance,
+        }),
+    )
+    const windingTargetOrders = getWindingTargetOrders({
+      bus,
+      boundaryDirection,
+      layerNames,
+      targetLayer,
+    })
+    const windingTargetOrderCount = windingTargetOrders.orders.length
+    const ordinaryWindingTargetOrderCount = usesDistributedWindingTargets
+      ? windingTargetOrders.ordinaryOrderCount
+      : 1
     const uniformDogboneTerminalPatterns: CoordinatedTerminalPattern[] =
       viaHandednesses.map((viaHandedness) => ({
         label: `uniform-${viaHandedness}`,
@@ -2904,7 +2950,7 @@ export function* routeBusAlternativesSteps(
       coordinatedViaPoints
         ? [
             ...Array.from(
-              { length: windingTargetOrderCount },
+              { length: ordinaryWindingTargetOrderCount },
               (_, windingOrderIndex) => ({
                 label: `component-matched-vias-winding-${windingOrderIndex}`,
                 useViaInPad: false,
@@ -2928,6 +2974,26 @@ export function* routeBusAlternativesSteps(
               windingOrderIndex: 0,
               preferTargetDirectedLaneBias: true,
             },
+            // Keep ordinary fixed-site attempts first. Forward retries reserve
+            // future exits so an earlier lane cannot close their final gap.
+            ...(!getCornerSide(bus) && windingTargetOrderCount > 1
+              ? Array.from(
+                  { length: windingTargetOrderCount },
+                  (_, windingOrderIndex) =>
+                    [true, false].map((preferTargetDirectedLaneBias) => ({
+                      label: `expanded-winding-${windingOrderIndex}-${preferTargetDirectedLaneBias}`,
+                      useViaInPad: false,
+                      getViaHandedness: () => 0 as const,
+                      getViaPoint: (connection: PreparedConnection) =>
+                        coordinatedViaPoints.get(connection.connectionIndex)!,
+                      maximumRouteOrderAttempts: 1,
+                      windingOrderIndex,
+                      preferTargetDirectedLaneBias,
+                      reserveTerminalExitPoints: !preferTargetDirectedLaneBias,
+                      allowLayerInterleaving: true,
+                    })),
+                ).flat()
+              : []),
           ]
         : []
     const planeTerminationsAlreadyOccupyTheFanout = acceptedPlans.some(
@@ -2995,6 +3061,23 @@ export function* routeBusAlternativesSteps(
         }
       }
     }
+    if (alignWindingGridToPads && cornerSide) {
+      const layerLocalExitOffset = getCornerLaneOffsets(
+        bus,
+        acceptedPlans.filter((plan) => plan.targetLayer === targetLayer),
+      ).exit
+      if (layerLocalExitOffset !== cornerLaneOffsets.exit) {
+        // Preserve successful shared-band routes first. If those patterns
+        // fail, reuse the corner slots occupied only on other copper layers.
+        terminalPatterns.push(
+          ...terminalPatterns.map((pattern) => ({
+            ...pattern,
+            label: `${pattern.label}-layer-local-corner`,
+            cornerExitLaneOffset: layerLocalExitOffset,
+          })),
+        )
+      }
+    }
     const seenTerminalSignatures = new Set<string>()
     for (const terminalPattern of terminalPatterns) {
       const terminals = bus.connections.map((preparedConnection) => {
@@ -3004,7 +3087,8 @@ export function* routeBusAlternativesSteps(
           ? getCornerTargetTrack({
               bus,
               connection: preparedConnection,
-              cornerExitLaneOffset: cornerLaneOffsets.exit,
+              cornerExitLaneOffset:
+                terminalPattern.cornerExitLaneOffset ?? cornerLaneOffsets.exit,
               traceWidth,
               viaDiameter,
               clearance,
@@ -3014,6 +3098,7 @@ export function* routeBusAlternativesSteps(
               cornerBandTargetTrackOffset,
             })
           : getBoundaryTargetTrack({
+              allowLayerInterleaving: terminalPattern.allowLayerInterleaving,
               bus,
               connection: preparedConnection,
               boundaryDirection,
@@ -3101,7 +3186,7 @@ export function* routeBusAlternativesSteps(
         )
         .join(
           "|",
-        )}:${terminalPattern.maximumRouteOrderAttempts ?? "all"}:${gridStepDivisor}:${alignGridToPads}:${Boolean(terminalPattern.localDogboneRepair)}`
+        )}:${terminalPattern.maximumRouteOrderAttempts ?? "all"}:${gridStepDivisor}:${alignGridToPads}:${Boolean(terminalPattern.localDogboneRepair)}:${Boolean(terminalPattern.preferTargetDirectedLaneBias)}:${Boolean(terminalPattern.reserveTerminalExitPoints)}`
       if (seenTerminalSignatures.has(terminalSignature)) continue
       seenTerminalSignatures.add(terminalSignature)
       const windingSteps = routeViaMinimalWindingAlternativesSteps(
@@ -3124,6 +3209,7 @@ export function* routeBusAlternativesSteps(
           includeReverseTargetRotation: terminalPattern.localDogboneRepair,
           reservedVias,
           softReservedVias,
+          reserveTerminalExitPoints: terminalPattern.reserveTerminalExitPoints,
           gridStepDivisor,
           preferTargetDirectedLaneBias:
             terminalPattern.preferTargetDirectedLaneBias,

package/lib/route-via-minimal-winding.ts

@@ -76,6 +76,8 @@ export interface RouteViaMinimalWindingParams {
   alignGridToPads?: boolean
   /** Defer the outermost reversed target while routing the inner terminals. */
   includeReverseTargetRotation?: boolean
+  /** Keep earlier lanes clear of every remaining terminal exit. */
+  reserveTerminalExitPoints?: boolean
 }
 
 export interface RouteViaMinimalWindingProgress {
@@ -646,6 +648,7 @@ export function* routeViaMinimalWindingAlternativesSteps(
     adaptiveRouteOrder = false,
     alignGridToPads = false,
     includeReverseTargetRotation = false,
+    reserveTerminalExitPoints = false,
   } = params
   if (
     maximumRouteOrderAttempts !== undefined &&
@@ -906,6 +909,14 @@ export function* routeViaMinimalWindingAlternativesSteps(
         return false
       }
     }
+    for (const other of reserveTerminalExitPoints ? terminals : []) {
+      if (sharesNet(connectionName, other.connection.connection.name)) continue
+      if (
+        distancePointToSegment(other.exitPoint, segment.start, segment.end) <
+        traceWidth + clearance - EPSILON
+      )
+        return false
+    }
     const segmentMinX = Math.min(segment.start.x, segment.end.x)
     const segmentMaxX = Math.max(segment.start.x, segment.end.x)
     const segmentMinY = Math.min(segment.start.y, segment.end.y)

package/package.json

@@ -1,6 +1,6 @@
 {
   "name": "@tscircuit/fanout-solver",
-  "version": "0.0.60",
+  "version": "0.0.62",
   "description": "BGA fanout solver with coordinated bus-layer escapes for SimpleRouteJson",
   "module": "lib/index.ts",
   "type": "module",