circuit-json-to-lbrn 0.0.51 → 0.0.53

package/.github/workflows/stalebot.yml

@@ -0,0 +1,29 @@
+name: 'Close stale issues and PRs'
+on:
+  schedule:
+    - cron: '30 1 * * *'  # Runs at 1:30 AM UTC every day
+
+jobs:
+  stale:
+    runs-on: ubuntu-latest
+    steps:
+      - uses: actions/stale@v9
+        with:
+          # Issues config
+          stale-issue-message: 'This issue has been automatically marked as stale because it has had no recent activity. It will be closed if no further activity occurs.'
+          close-issue-message: 'This issue was closed because it has been inactive for 14 days since being marked as stale.'
+          days-before-issue-stale: 60
+          days-before-issue-close: 14
+          
+          # Pull request config
+          stale-pr-message: 'This PR has been automatically marked as stale because it has had no recent activity. It will be closed if no further activity occurs.'
+          close-pr-message: 'This PR was closed because it has been inactive for 1 day since being marked as stale.'
+          days-before-pr-stale: 2
+          days-before-pr-close: 1
+          
+          # General config
+          exempt-issue-labels: 'pinned,security,help-wanted'
+          exempt-pr-labels: 'pinned,security,help-wanted'
+          stale-issue-label: 'no-issue-activity'
+          stale-pr-label: 'no-pr-activity'
+          operations-per-run: 100

package/CLAUDE.md

@@ -0,0 +1 @@
+- Use `bun`/`bunx` (DO NOT USE `npm` or `npx`)

package/dist/index.d.ts

@@ -26,6 +26,12 @@ interface ConvertCircuitJsonToLbrnOptions {
      * This determines how wide the band of copper removal will be around traces/pads.
      */
     copperCutFillMargin?: number;
+    /**
+     * Whether to generate an oxidation cleaning layer.
+     * Creates a filled area covering the entire "inside" of the board outline
+     * for laser ablation to clean oxidation from the copper surface.
+     */
+    includeOxidationCleaningLayer?: boolean;
     laserProfile?: {
         copper?: {
             speed?: number;

package/dist/index.js

@@ -2663,6 +2663,95 @@ var createCopperCutFillForLayer = async ({
   }
 };
 
+// lib/createOxidationCleaningLayerForLayer.ts
+import { Polygon as Polygon6, Point as Point3 } from "@flatten-js/core";
+import { ShapePath as ShapePath29, ShapeGroup as ShapeGroup2 } from "lbrnts";
+var contourToPolygon2 = (contour) => {
+  if (contour.length < 3) return null;
+  const points = contour.map(([x, y]) => new Point3(x, y));
+  try {
+    const polygon = new Polygon6(points);
+    if (polygon.faces.size > 0) {
+      return polygon;
+    }
+  } catch {
+  }
+  return null;
+};
+var createOxidationCleaningLayerForLayer = async ({
+  layer,
+  ctx
+}) => {
+  const { project, boardOutlineContour } = ctx;
+  const cutSetting = layer === "top" ? ctx.topOxidationCleaningCutSetting : ctx.bottomOxidationCleaningCutSetting;
+  if (!cutSetting) {
+    return;
+  }
+  if (!boardOutlineContour || boardOutlineContour.length < 3) {
+    console.warn(
+      `Cannot create oxidation cleaning layer for ${layer}: no board outline available`
+    );
+    return;
+  }
+  try {
+    const manifold = await getManifold();
+    const { CrossSection } = manifold;
+    const fillArea = new CrossSection([boardOutlineContour], "Positive");
+    const simplifiedArea = fillArea.simplify(1e-3);
+    const resultContours = simplifiedArea.toPolygons();
+    if (resultContours.length === 0) {
+      fillArea.delete();
+      simplifiedArea.delete();
+      return;
+    }
+    const shapeGroup = new ShapeGroup2();
+    for (const contour of resultContours) {
+      const polygon = contourToPolygon2(contour);
+      if (!polygon) continue;
+      for (const island of polygon.splitToIslands()) {
+        const { verts, prims } = polygonToShapePathData(island);
+        if (verts.length > 0) {
+          shapeGroup.children.push(
+            new ShapePath29({
+              cutIndex: cutSetting.index,
+              verts,
+              prims,
+              isClosed: true
+              // Filled shapes should be closed
+            })
+          );
+        }
+      }
+    }
+    if (shapeGroup.children.length > 0) {
+      project.children.push(shapeGroup);
+    }
+    fillArea.delete();
+    simplifiedArea.delete();
+  } catch (error) {
+    console.warn(
+      `Failed to create oxidation cleaning layer for ${layer} layer:`,
+      error
+    );
+  }
+};
+
+// lib/layer-indexes.ts
+var LAYER_INDEXES = {
+  // Cut layers (vector/outline)
+  topCopper: 0,
+  bottomCopper: 1,
+  throughBoard: 2,
+  // Scan layers (raster/fill)
+  soldermask: 3,
+  topTraceClearance: 4,
+  bottomTraceClearance: 5,
+  topCopperCutFill: 6,
+  bottomCopperCutFill: 7,
+  topOxidationCleaning: 8,
+  bottomOxidationCleaning: 9
+};
+
 // lib/index.ts
 var convertCircuitJsonToLbrn = async (circuitJson, options = {}) => {
   const db = cju2(circuitJson);
@@ -2680,6 +2769,7 @@ var convertCircuitJsonToLbrn = async (circuitJson, options = {}) => {
   const laserProfile = options.laserProfile;
   const includeCopperCutFill = options.includeCopperCutFill ?? false;
   const copperCutFillMargin = options.copperCutFillMargin ?? 0.5;
+  const includeOxidationCleaningLayer = options.includeOxidationCleaningLayer ?? false;
   const defaultCopperSettings = {
     speed: 300,
     numPasses: 100,
@@ -2699,7 +2789,7 @@ var convertCircuitJsonToLbrn = async (circuitJson, options = {}) => {
     throw new Error("traceMargin requires includeCopper to be true");
   }
   const topCopperCutSetting = new CutSetting({
-    index: 0,
+    index: LAYER_INDEXES.topCopper,
     name: "Cut Top Copper",
     numPasses: copperSettings.numPasses,
     speed: copperSettings.speed,
@@ -2708,7 +2798,7 @@ var convertCircuitJsonToLbrn = async (circuitJson, options = {}) => {
   });
   project.children.push(topCopperCutSetting);
   const bottomCopperCutSetting = new CutSetting({
-    index: 1,
+    index: LAYER_INDEXES.bottomCopper,
     name: "Cut Bottom Copper",
     numPasses: copperSettings.numPasses,
     speed: copperSettings.speed,
@@ -2717,7 +2807,7 @@ var convertCircuitJsonToLbrn = async (circuitJson, options = {}) => {
   });
   project.children.push(bottomCopperCutSetting);
   const throughBoardCutSetting = new CutSetting({
-    index: 2,
+    index: LAYER_INDEXES.throughBoard,
     name: "Cut Through Board",
     numPasses: boardSettings.numPasses,
     speed: boardSettings.speed,
@@ -2727,7 +2817,7 @@ var convertCircuitJsonToLbrn = async (circuitJson, options = {}) => {
   project.children.push(throughBoardCutSetting);
   const soldermaskCutSetting = new CutSetting({
     type: "Scan",
-    index: 3,
+    index: LAYER_INDEXES.soldermask,
     name: "Cut Soldermask",
     numPasses: 1,
     speed: 150,
@@ -2737,14 +2827,13 @@ var convertCircuitJsonToLbrn = async (circuitJson, options = {}) => {
     crossHatch: true
   });
   project.children.push(soldermaskCutSetting);
-  let nextCutIndex = 4;
   let topTraceClearanceAreaCutSetting;
   let bottomTraceClearanceAreaCutSetting;
   if (shouldGenerateTraceClearanceZones) {
     if (includeLayers.includes("top")) {
       topTraceClearanceAreaCutSetting = new CutSetting({
         type: "Scan",
-        index: nextCutIndex++,
+        index: LAYER_INDEXES.topTraceClearance,
         name: "Clear Top Trace Clearance Areas",
         numPasses: 12,
         speed: 100,
@@ -2758,7 +2847,7 @@ var convertCircuitJsonToLbrn = async (circuitJson, options = {}) => {
     if (includeLayers.includes("bottom")) {
       bottomTraceClearanceAreaCutSetting = new CutSetting({
         type: "Scan",
-        index: nextCutIndex++,
+        index: LAYER_INDEXES.bottomTraceClearance,
         name: "Clear Bottom Trace Clearance Areas",
         numPasses: 12,
         speed: 100,
@@ -2776,7 +2865,7 @@ var convertCircuitJsonToLbrn = async (circuitJson, options = {}) => {
     if (includeLayers.includes("top")) {
       topCopperCutFillCutSetting = new CutSetting({
         type: "Scan",
-        index: nextCutIndex++,
+        index: LAYER_INDEXES.topCopperCutFill,
         name: "Top Copper Cut Fill",
         numPasses: copperSettings.numPasses,
         speed: copperSettings.speed,
@@ -2790,7 +2879,7 @@ var convertCircuitJsonToLbrn = async (circuitJson, options = {}) => {
     if (includeLayers.includes("bottom")) {
       bottomCopperCutFillCutSetting = new CutSetting({
         type: "Scan",
-        index: nextCutIndex++,
+        index: LAYER_INDEXES.bottomCopperCutFill,
         name: "Bottom Copper Cut Fill",
         numPasses: copperSettings.numPasses,
         speed: copperSettings.speed,
@@ -2802,6 +2891,38 @@ var convertCircuitJsonToLbrn = async (circuitJson, options = {}) => {
       project.children.push(bottomCopperCutFillCutSetting);
     }
   }
+  let topOxidationCleaningCutSetting;
+  let bottomOxidationCleaningCutSetting;
+  if (includeOxidationCleaningLayer) {
+    if (includeLayers.includes("top")) {
+      topOxidationCleaningCutSetting = new CutSetting({
+        type: "Scan",
+        index: LAYER_INDEXES.topOxidationCleaning,
+        name: "Top Oxidation Cleaning",
+        numPasses: copperSettings.numPasses,
+        speed: 500,
+        scanOpt: "individual",
+        interval: laserSpotSize,
+        angle: 45,
+        crossHatch: true
+      });
+      project.children.push(topOxidationCleaningCutSetting);
+    }
+    if (includeLayers.includes("bottom")) {
+      bottomOxidationCleaningCutSetting = new CutSetting({
+        type: "Scan",
+        index: LAYER_INDEXES.bottomOxidationCleaning,
+        name: "Bottom Oxidation Cleaning",
+        numPasses: copperSettings.numPasses,
+        speed: 500,
+        scanOpt: "individual",
+        interval: laserSpotSize,
+        angle: 45,
+        crossHatch: true
+      });
+      project.children.push(bottomOxidationCleaningCutSetting);
+    }
+  }
   const connMap = getFullConnectivityMapFromCircuitJson(circuitJson);
   let origin = options.origin;
   if (!origin) {
@@ -2833,6 +2954,8 @@ var convertCircuitJsonToLbrn = async (circuitJson, options = {}) => {
     topCopperCutFillCutSetting,
     bottomCopperCutFillCutSetting,
     copperCutFillMargin,
+    topOxidationCleaningCutSetting,
+    bottomOxidationCleaningCutSetting,
     topTraceEndpoints: /* @__PURE__ */ new Set(),
     bottomTraceEndpoints: /* @__PURE__ */ new Set()
   };
@@ -2909,6 +3032,14 @@ var convertCircuitJsonToLbrn = async (circuitJson, options = {}) => {
       await createCopperCutFillForLayer({ layer: "bottom", ctx });
     }
   }
+  if (includeOxidationCleaningLayer) {
+    if (includeLayers.includes("top")) {
+      await createOxidationCleaningLayerForLayer({ layer: "top", ctx });
+    }
+    if (includeLayers.includes("bottom")) {
+      await createOxidationCleaningLayerForLayer({ layer: "bottom", ctx });
+    }
+  }
   return project;
 };
 export {

package/lib/ConvertContext.ts

@@ -50,6 +50,10 @@ export interface ConvertContext {
   topCopperCutFillCutSetting?: CutSetting
   bottomCopperCutFillCutSetting?: CutSetting
 
+  // Cut settings for oxidation cleaning layer
+  topOxidationCleaningCutSetting?: CutSetting
+  bottomOxidationCleaningCutSetting?: CutSetting
+
   // Percent-based solder mask margin (scales with element size)
   solderMaskMarginPercent: number
 

package/lib/createOxidationCleaningLayerForLayer.ts

@@ -0,0 +1,120 @@
+import { Polygon, Point } from "@flatten-js/core"
+import type { ConvertContext } from "./ConvertContext"
+import { polygonToShapePathData } from "./polygon-to-shape-path"
+import { ShapePath, ShapeGroup } from "lbrnts"
+import { getManifold } from "./getManifold"
+
+type Contour = Array<[number, number]>
+
+/**
+ * Converts a single contour to a flatten-js Polygon
+ */
+const contourToPolygon = (contour: Contour): Polygon | null => {
+  if (contour.length < 3) return null
+
+  const points = contour.map(([x, y]) => new Point(x, y))
+  try {
+    const polygon = new Polygon(points)
+    if (polygon.faces.size > 0) {
+      return polygon
+    }
+  } catch {
+    // Skip invalid polygons
+  }
+  return null
+}
+
+/**
+ * Creates an oxidation cleaning layer for a given layer.
+ *
+ * This generates a filled area covering the entire "inside" of the board outline
+ * that can be used to laser clean oxidation from the copper surface.
+ *
+ * The algorithm:
+ * 1. Get the board outline contour
+ * 2. Optionally inset (shrink) the outline by the margin to leave a border
+ * 3. Create SCAN mode shapes that will fill the entire board area
+ */
+export const createOxidationCleaningLayerForLayer = async ({
+  layer,
+  ctx,
+}: {
+  layer: "top" | "bottom"
+  ctx: ConvertContext
+}): Promise<void> => {
+  const { project, boardOutlineContour } = ctx
+
+  // Get the appropriate cut setting for this layer
+  const cutSetting =
+    layer === "top"
+      ? ctx.topOxidationCleaningCutSetting
+      : ctx.bottomOxidationCleaningCutSetting
+
+  if (!cutSetting) {
+    return
+  }
+
+  if (!boardOutlineContour || boardOutlineContour.length < 3) {
+    console.warn(
+      `Cannot create oxidation cleaning layer for ${layer}: no board outline available`,
+    )
+    return
+  }
+
+  try {
+    const manifold = await getManifold()
+    const { CrossSection } = manifold
+
+    // Create board outline as CrossSection (the fill area)
+    const fillArea = new CrossSection([boardOutlineContour], "Positive")
+
+    // Simplify to clean up any spurious tiny segments
+    const simplifiedArea = fillArea.simplify(0.001)
+
+    // Get the resulting contours
+    const resultContours: Contour[] = simplifiedArea.toPolygons()
+
+    if (resultContours.length === 0) {
+      fillArea.delete()
+      simplifiedArea.delete()
+      return
+    }
+
+    // Create a ShapeGroup to hold all contours
+    const shapeGroup = new ShapeGroup()
+
+    for (const contour of resultContours) {
+      const polygon = contourToPolygon(contour)
+      if (!polygon) continue
+
+      for (const island of polygon.splitToIslands()) {
+        const { verts, prims } = polygonToShapePathData(island)
+
+        if (verts.length > 0) {
+          shapeGroup.children.push(
+            new ShapePath({
+              cutIndex: cutSetting.index,
+              verts,
+              prims,
+              isClosed: true, // Filled shapes should be closed
+            }),
+          )
+        }
+      }
+    }
+
+    // Add the group to the project if it has shapes
+    if (shapeGroup.children.length > 0) {
+      project.children.push(shapeGroup)
+    }
+
+    // Clean up WASM memory
+    fillArea.delete()
+    simplifiedArea.delete()
+  } catch (error) {
+    console.warn(
+      `Failed to create oxidation cleaning layer for ${layer} layer:`,
+      error,
+    )
+  }
+}

package/lib/index.ts

@@ -17,6 +17,8 @@ import { addPcbCutout } from "./element-handlers/addPcbCutout"
 import { createCopperShapesForLayer } from "./createCopperShapesForLayer"
 import { createTraceClearanceAreasForLayer } from "./createTraceClearanceAreasForLayer"
 import { createCopperCutFillForLayer } from "./createCopperCutFillForLayer"
+import { createOxidationCleaningLayerForLayer } from "./createOxidationCleaningLayerForLayer"
+import { LAYER_INDEXES } from "./layer-indexes"
 
 export interface ConvertCircuitJsonToLbrnOptions {
   includeSilkscreen?: boolean
@@ -40,6 +42,12 @@ export interface ConvertCircuitJsonToLbrnOptions {
    * This determines how wide the band of copper removal will be around traces/pads.
    */
   copperCutFillMargin?: number
+  /**
+   * Whether to generate an oxidation cleaning layer.
+   * Creates a filled area covering the entire "inside" of the board outline
+   * for laser ablation to clean oxidation from the copper surface.
+   */
+  includeOxidationCleaningLayer?: boolean
   laserProfile?: {
     copper?: {
       speed?: number
@@ -77,6 +85,8 @@ export const convertCircuitJsonToLbrn = async (
   const laserProfile = options.laserProfile
   const includeCopperCutFill = options.includeCopperCutFill ?? false
   const copperCutFillMargin = options.copperCutFillMargin ?? 0.5
+  const includeOxidationCleaningLayer =
+    options.includeOxidationCleaningLayer ?? false
 
   // Default laser settings
   const defaultCopperSettings = {
@@ -106,7 +116,7 @@ export const convertCircuitJsonToLbrn = async (
 
   // Create cut settings
   const topCopperCutSetting = new CutSetting({
-    index: 0,
+    index: LAYER_INDEXES.topCopper,
     name: "Cut Top Copper",
     numPasses: copperSettings.numPasses,
     speed: copperSettings.speed,
@@ -116,7 +126,7 @@ export const convertCircuitJsonToLbrn = async (
   project.children.push(topCopperCutSetting)
 
   const bottomCopperCutSetting = new CutSetting({
-    index: 1,
+    index: LAYER_INDEXES.bottomCopper,
     name: "Cut Bottom Copper",
     numPasses: copperSettings.numPasses,
     speed: copperSettings.speed,
@@ -126,7 +136,7 @@ export const convertCircuitJsonToLbrn = async (
   project.children.push(bottomCopperCutSetting)
 
   const throughBoardCutSetting = new CutSetting({
-    index: 2,
+    index: LAYER_INDEXES.throughBoard,
     name: "Cut Through Board",
     numPasses: boardSettings.numPasses,
     speed: boardSettings.speed,
@@ -137,7 +147,7 @@ export const convertCircuitJsonToLbrn = async (
 
   const soldermaskCutSetting = new CutSetting({
     type: "Scan",
-    index: 3,
+    index: LAYER_INDEXES.soldermask,
     name: "Cut Soldermask",
     numPasses: 1,
     speed: 150,
@@ -148,9 +158,6 @@ export const convertCircuitJsonToLbrn = async (
   })
   project.children.push(soldermaskCutSetting)
 
-  // Track the next available cut setting index
-  let nextCutIndex = 4
-
   // Create trace clearance cut settings if needed
   let topTraceClearanceAreaCutSetting: CutSetting | undefined
   let bottomTraceClearanceAreaCutSetting: CutSetting | undefined
@@ -159,7 +166,7 @@ export const convertCircuitJsonToLbrn = async (
     if (includeLayers.includes("top")) {
       topTraceClearanceAreaCutSetting = new CutSetting({
         type: "Scan",
-        index: nextCutIndex++,
+        index: LAYER_INDEXES.topTraceClearance,
         name: "Clear Top Trace Clearance Areas",
         numPasses: 12,
         speed: 100,
@@ -174,7 +181,7 @@ export const convertCircuitJsonToLbrn = async (
     if (includeLayers.includes("bottom")) {
       bottomTraceClearanceAreaCutSetting = new CutSetting({
         type: "Scan",
-        index: nextCutIndex++,
+        index: LAYER_INDEXES.bottomTraceClearance,
         name: "Clear Bottom Trace Clearance Areas",
         numPasses: 12,
         speed: 100,
@@ -195,7 +202,7 @@ export const convertCircuitJsonToLbrn = async (
     if (includeLayers.includes("top")) {
       topCopperCutFillCutSetting = new CutSetting({
         type: "Scan",
-        index: nextCutIndex++,
+        index: LAYER_INDEXES.topCopperCutFill,
         name: "Top Copper Cut Fill",
         numPasses: copperSettings.numPasses,
         speed: copperSettings.speed,
@@ -210,7 +217,7 @@ export const convertCircuitJsonToLbrn = async (
     if (includeLayers.includes("bottom")) {
       bottomCopperCutFillCutSetting = new CutSetting({
         type: "Scan",
-        index: nextCutIndex++,
+        index: LAYER_INDEXES.bottomCopperCutFill,
         name: "Bottom Copper Cut Fill",
         numPasses: copperSettings.numPasses,
         speed: copperSettings.speed,
@@ -223,6 +230,42 @@ export const convertCircuitJsonToLbrn = async (
     }
   }
 
+  // Create oxidation cleaning layer cut settings if needed
+  let topOxidationCleaningCutSetting: CutSetting | undefined
+  let bottomOxidationCleaningCutSetting: CutSetting | undefined
+
+  if (includeOxidationCleaningLayer) {
+    if (includeLayers.includes("top")) {
+      topOxidationCleaningCutSetting = new CutSetting({
+        type: "Scan",
+        index: LAYER_INDEXES.topOxidationCleaning,
+        name: "Top Oxidation Cleaning",
+        numPasses: copperSettings.numPasses,
+        speed: 500,
+        scanOpt: "individual",
+        interval: laserSpotSize,
+        angle: 45,
+        crossHatch: true,
+      })
+      project.children.push(topOxidationCleaningCutSetting)
+    }
+
+    if (includeLayers.includes("bottom")) {
+      bottomOxidationCleaningCutSetting = new CutSetting({
+        type: "Scan",
+        index: LAYER_INDEXES.bottomOxidationCleaning,
+        name: "Bottom Oxidation Cleaning",
+        numPasses: copperSettings.numPasses,
+        speed: 500,
+        scanOpt: "individual",
+        interval: laserSpotSize,
+        angle: 45,
+        crossHatch: true,
+      })
+      project.children.push(bottomOxidationCleaningCutSetting)
+    }
+  }
+
   // Build connectivity map and origin
   const connMap = getFullConnectivityMapFromCircuitJson(circuitJson)
   let origin = options.origin
@@ -257,6 +300,8 @@ export const convertCircuitJsonToLbrn = async (
     topCopperCutFillCutSetting,
     bottomCopperCutFillCutSetting,
     copperCutFillMargin,
+    topOxidationCleaningCutSetting,
+    bottomOxidationCleaningCutSetting,
     topTraceEndpoints: new Set(),
     bottomTraceEndpoints: new Set(),
   }
@@ -356,5 +401,15 @@ export const convertCircuitJsonToLbrn = async (
     }
   }
 
+  // Create oxidation cleaning layer for each layer
+  if (includeOxidationCleaningLayer) {
+    if (includeLayers.includes("top")) {
+      await createOxidationCleaningLayerForLayer({ layer: "top", ctx })
+    }
+    if (includeLayers.includes("bottom")) {
+      await createOxidationCleaningLayerForLayer({ layer: "bottom", ctx })
+    }
+  }
+
   return project
 }

package/lib/layer-indexes.ts

@@ -0,0 +1,22 @@
+/**
+ * Consistent layer index assignments for LightBurn cut settings.
+ * Each layer type always gets the same index (and thus the same color)
+ * regardless of what other layers are enabled.
+ */
+export const LAYER_INDEXES = {
+  // Cut layers (vector/outline)
+  topCopper: 0,
+  bottomCopper: 1,
+  throughBoard: 2,
+
+  // Scan layers (raster/fill)
+  soldermask: 3,
+  topTraceClearance: 4,
+  bottomTraceClearance: 5,
+  topCopperCutFill: 6,
+  bottomCopperCutFill: 7,
+  topOxidationCleaning: 8,
+  bottomOxidationCleaning: 9,
+} as const
+
+export type LayerIndex = (typeof LAYER_INDEXES)[keyof typeof LAYER_INDEXES]

package/package.json

@@ -1,7 +1,7 @@
 {
   "name": "circuit-json-to-lbrn",
   "main": "dist/index.js",
-  "version": "0.0.51",
+  "version": "0.0.53",
   "type": "module",
   "scripts": {
     "start": "bun run site/index.html",

package/tests/basics/copper-cut-fill/__snapshots__/copper-cut-fill-basic.snap.svg

@@ -3,6 +3,6 @@
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