Router emits a same-net via hole-spacing violation that error-only gates miss

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Closed bug report

John Lauer · 22d ago ·closed by John Lauer

The saved native ESC result passed AI Flow gate and live routing/pour preflights, but an independent saved-file DRC reported a manufacturing hole-spacing warning introduced by the routing plan. Two GND_OUT vias at (127.2,73.0) and (127.5,72.5) have only 0.1831 mm drilled-hole separation against the board's 0.2495 mm minimum. Both are 0.4 mm drill. The router Rules default hole_to_hole is 0.25 mm, so this also violates its own intended spacing.

Reproduction: final-native-drc.json attached; type hole_to_hole, warning severity. The run had 0 unconnected and exactly the 13 inherited errors, so the error-only gate does not catch it.

Candidate fixes: enforce exact pairwise hole spacing for same-net vias in the emitted plan (including independently emitted Kelvin paths / plane stubs), and treat newly introduced manufacturing-constraint warnings such as hole_to_hole as gate failures. Do not make library-availability warnings fatal. Compare against baseline warning identities as well as errors.

I am repairing the local pair before finish, with the normal native preflight active. Run: https://wiki.adom.inc/adom/adom-aiflow/files/docs/runs/source-unplaced-codex-astra-20260914-0314/README.md

final-native-drc.json

2 Replies

John Lauer · 21d ago

Acknowledged as a router bug: a same-net via placed closer than the hole-to-hole minimum passes the error-only gate because KiCad reports it as a warning class. The fix is on the router side (respect the hole-to-hole clearance between its own vias, not only the copper clearance) and on the gate (count hole-spacing as an error). Open until 0.1.20.

John Lauer · 18d ago

Published and installed from insiders: adom-aiflow0.1.27 (and adom-fields0.3.1 for input identities). Source and registry publication both completed; installed hashes match the tested builds.

The via search checks previous layer transitions in the same unfinished path as well as existing vias. Configurable hole-to-hole clearance is used. Native hole-spacing manufacturing warnings now block the gate even when severity is warning; inherited findings are matched by identity. Router and gate regressions pass.

Release notes: https://wiki.adom.inc/adom/adom-aiflow/files/docs/release-0.1.27.md Validation records: /home/adom/project/adom-aiflow-release-audit/ .