Generate

This fills copper zones (In1.Cu=GND plane, In2.Cu=3V3/5V planes) and preserves orphan nets (USB_CC1/CC2).

3. Export Gerbers + drill files via Docker

docker compose run --rm kicad-pcb pcb export gerbers \
    --output /gerbers/ \
    --layers "F.Cu,In1.Cu,In2.Cu,B.Cu,F.Paste,B.Paste,F.SilkS,B.SilkS,F.Mask,B.Mask,Edge.Cuts" \
    --subtract-soldermask --use-drill-file-origin \
    "/project/esp32-emu-turbo.kicad_pcb"

docker compose run --rm kicad-pcb pcb export drill \
    --output /gerbers/ --format excellon --drill-origin plot \
    --excellon-units mm --generate-map --map-format gerberx2 \
    "/project/esp32-emu-turbo.kicad_pcb"

4. Create gerbers.zip for JLCPCB

cd hardware/kicad/gerbers
zip -j ../jlcpcb/gerbers.zip *.gtl *.g1 *.g2 *.gbl *.gto *.gbo *.gts *.gbs *.gtp *.gbp *.gm1 *.drl *.gbrjob 2>/dev/null

5. Copy to release_jlcpcb/

cp hardware/kicad/jlcpcb/bom.csv release_jlcpcb/bom.csv
cp hardware/kicad/jlcpcb/cpl.csv release_jlcpcb/cpl.csv
rm -rf release_jlcpcb/gerbers
cp -r hardware/kicad/gerbers release_jlcpcb/gerbers
cp hardware/kicad/jlcpcb/gerbers.zip release_jlcpcb/gerbers.zip

6. Run verification

After the pipeline completes, run DFM + DFA verification:

python3 scripts/verify_dfm_v2.py
python3 scripts/verify_dfa.py

Report results as a summary table (43 DFM + 9 DFA tests).

Important Notes

• Always run from the project root: /Users/pierrejonnycau/Documents/WORKS/esp32-emu-turbo
• Zone fill MUST run before gerber export (internal copper planes would be empty otherwise)
• The kicad_fill_zones.py preserves orphan nets (USB_CC1, USB_CC2) that pcbnew would normally strip
• If Docker is not running, start it first with docker compose build

Key Files

• Pipeline entry: scripts/generate_pcb/__init__.py → calls generate_board() + export_cpl()
• Board layout: scripts/generate_pcb/board.py
• Routing: scripts/generate_pcb/routing.py
• Footprints: scripts/generate_pcb/footprints.py
• JLCPCB export: scripts/generate_pcb/jlcpcb_export.py
• Zone fill: scripts/kicad_fill_zones.py
• Gerber export (fast): scripts/export-gerbers-fast.sh
• Gerber export (Docker): scripts/export-gerbers.sh
• DFA verification: scripts/verify_dfa.py