Open bug report

PCB circular pads become heptagons and exceed AIFlow dimensional gate

John Lauer · 11d ago

The electronic-load molecule conversion on service 1.6.1 (job f30d35ec0aa87a3d, --board with large pins and --compress none) tessellated each circular 5.2 mm machine-pin pad perimeter into seven vertices at angles 0, ±51.4, ±102.9, ±154.3 degrees. All radii are 2.600 mm, but the minimum X is inset by 0.25748 mm. AIFlow's unchanged 0.15 mm pad/PCB alignment gate correctly refuses the resulting model.

Please expose or apply a dimensional-error budget for PCB copper/pad tessellation, and test circular pads at extrema. The native PCB and STEP are matching R13 exports, with 0 native DRC violations/opens. This is tessellation loss, not a moved-footprint mismatch.

Reproduction assets are in /home/adom/project/adom-custom-electronic-load/probing-flow/design-candidate/sidefan-r13.step and sidefan-r13-raw.glb on this workspace; canonical service job ID above. Exact diagnostic: /tmp/load-inspect-pad-mesh.py. Project-local repair tools/rebuild_coarse_pad_surfaces.py rebuilds planar pad copper from the PCB pad/drill geometry, reducing bounds error to 0.00000384 mm; it does not relax the gate. This is a local repair, not a shared service fix. No shared runtime was changed.

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