Fusion lane: fusion export calls fusion_export_gerbers without the layer count, so a 4-layer board exports as 2 layers

Glenn Jones · ·closed by Colby Knox

We kept a list of tool issues as we worked on a project, the 772 power module (LM251772), a 4-layer board built with AI Flow on the Fusion lane, and set them aside so they wouldn't slow the build down. Now that the project is finished, we're filing them together. Some were seen on earlier versions; where we could, we checked that they still apply.

Versions: adom-aiflow 0.2.44 when seen; the call is unchanged in 0.2.51 (tools/fusion-project.py, about line 2000). fusion-bridge 1.13.67.

What happens: fusion export calls fusion_export_gerbers with only outputPath. The bridge auto-detects the layer count, and on our 4-layer board (772 power module, LM251772) it detected 2 layers. The zip had top and bottom copper only, with no inner PGND/AGND planes. At 0.2.44 the export check still passed it.

Expected: pass the board's copper layer count to the bridge ("layers": "4" fixed it for us), and fail the export if the Gerber copper count differs from the board. 0.2.51's check_gerbers compares against the board's copper layers, which should catch the result; the export itself still needs the layer count.

Related: the detection bug on the bridge side is filed separately on adom/fusion-bridge.

No design files attached; happy to describe more on request.

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Colby Knox marked this in progress ·
Colby Knox mentioned this in pull request #67 ·
Colby Knox ·

Glenn, thanks. This is fixed in two places:

  • Fusion bridge 1.13.74: fusion_export_gerbers takes the count from the board's own stack, so inner planes that are only pours are no longer dropped. A board with 6 or more layers is refused instead of exported with layers missing.
  • adom-aiflow 0.2.52: fusion export now passes the board's layer count and checks the zip's inner copper against the board.

How it was tested: live on a 4-layer board whose inner copper is a pour. It wrote 13 files, including .G1 and .G2, and passed the check. The check's failure message is covered by a unit test only.

Upgrade: tell your AI "give me the latest adom-aiflow" (or adom-wiki pkg install adom/adom-aiflow); adom-aiflow --version says 0.2.52.

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