exporter_step.cpp

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/*
 * This program source code file is part of KiCad, a free EDA CAD application.
 *
 * Copyright (C) 2022 Mark Roszko <[email protected]>
 * Copyright (C) 2016 Cirilo Bernardo <[email protected]>
 * Copyright (C) 2016-2023 KiCad Developers, see AUTHORS.txt for contributors.
 *
 * This program is free software; you can redistribute it and/or
 * modify it under the terms of the GNU General Public License
 * as published by the Free Software Foundation; either version 2
 * of the License, or (at your option) any later version.
 *
 * This program is distributed in the hope that it will be useful,
 * but WITHOUT ANY WARRANTY; without even the implied warranty of
 * MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the
 * GNU General Public License for more details.
 *
 * You should have received a copy of the GNU General Public License
 * along with this program; if not, you may find one here:
 * http://www.gnu.org/licenses/old-licenses/gpl-2.0.html
 * or you may search the http://www.gnu.org website for the version 2 license,
 * or you may write to the Free Software Foundation, Inc.,
 * 51 Franklin Street, Fifth Floor, Boston, MA 02110-1301, USA
 */
 
#include "exporter_step.h"
#include <board.h>
#include <board_design_settings.h>
#include <footprint.h>
#include <pcb_track.h>
#include <pcb_shape.h>
#include <pad.h>
#include <fp_lib_table.h>
#include "step_pcb_model.h"
 
#include <pgm_base.h>
#include <base_units.h>
#include <filename_resolver.h>
#include <trace_helpers.h>
 
#include <Message.hxx> // OpenCascade messenger
#include <Message_PrinterOStream.hxx> // OpenCascade output messenger
#include <Standard_Failure.hxx> // In open cascade
 
#include <Standard_Version.hxx>
 
#include <wx/crt.h>
#include <wx/log.h>
 
#define OCC_VERSION_MIN 0x070500
 
#if OCC_VERSION_HEX < OCC_VERSION_MIN
#include <Message_Messenger.hxx>
#endif
 
 
void ReportMessage( const wxString& aMessage )
{
 wxPrintf( aMessage );
 fflush( stdout ); // Force immediate printing (needed on mingw)
}
 
class KiCadPrinter : public Message_Printer
{
public:
 KiCadPrinter( EXPORTER_STEP* aConverter ) : m_converter( aConverter ) {}
 
protected:
#if OCC_VERSION_HEX < OCC_VERSION_MIN
 virtual void Send( const TCollection_ExtendedString& theString,
 const Message_Gravity theGravity,
 const Standard_Boolean theToPutEol ) const override
 {
 Send( TCollection_AsciiString( theString ), theGravity, theToPutEol );
 }
 
 virtual void Send( const TCollection_AsciiString& theString,
 const Message_Gravity theGravity,
 const Standard_Boolean theToPutEol ) const override
#else
 virtual void send( const TCollection_AsciiString& theString,
 const Message_Gravity theGravity ) const override
#endif
 {
 if( theGravity >= Message_Warning
 || ( wxLog::IsAllowedTraceMask( traceKiCad2Step ) && theGravity == Message_Info ) )
 {
 ReportMessage( theString.ToCString() );
 
#if OCC_VERSION_HEX < OCC_VERSION_MIN
 if( theToPutEol )
 ReportMessage( wxT( "\n" ) );
#else
 ReportMessage( wxT( "\n" ) );
#endif
 }
 
 if( theGravity == Message_Warning )
 m_converter->SetWarn();
 
 if( theGravity >= Message_Alarm )
 m_converter->SetError();
 
 if( theGravity == Message_Fail )
 m_converter->SetFail();
 }
 
private:
 EXPORTER_STEP* m_converter;
};
 
 
EXPORTER_STEP::EXPORTER_STEP( BOARD* aBoard, const EXPORTER_STEP_PARAMS& aParams ) :
 m_params( aParams ),
 m_error( false ),
 m_fail( false ),
 m_warn( false ),
 m_hasDrillOrigin( false ),
 m_hasGridOrigin( false ),
 m_board( aBoard ),
 m_pcbModel( nullptr ),
 m_boardThickness( DEFAULT_BOARD_THICKNESS_MM )
{
 m_solderMaskColor = COLOR4D( 0.08, 0.20, 0.14, 0.83 );
 m_copperColor = COLOR4D( 0.7, 0.61, 0.0, 1.0 );
 
 // Init m_pcbBaseName to the board short filename (no path, no ext)
 // m_pcbName is used later to identify items in step file
 wxFileName fn( aBoard->GetFileName() );
 m_pcbBaseName = fn.GetName();
 
 m_resolver = std::make_unique<FILENAME_RESOLVER>();
 m_resolver->Set3DConfigDir( wxT( "" ) );
 // needed to add the project to the search stack
 m_resolver->SetProject( aBoard->GetProject() );
 m_resolver->SetProgramBase( &Pgm() );
}
 
 
EXPORTER_STEP::~EXPORTER_STEP()
{
}
 
 
bool EXPORTER_STEP::buildFootprint3DShapes( FOOTPRINT* aFootprint, VECTOR2D aOrigin )
{
 bool hasdata = false;
 
 // Dump the pad holes into the PCB
 for( PAD* pad : aFootprint->Pads() )
 {
 if( m_pcbModel->AddPadHole( pad, aOrigin ) )
 hasdata = true;
 
 if( ExportTracksAndVias() )
 {
 if( m_pcbModel->AddPadShape( pad, aOrigin ) )
 hasdata = true;
 }
 }
 
 // Build 3D shapes of the footprint graphic items on external layers:
 if( ExportTracksAndVias() )
 {
 int maxError = m_board->GetDesignSettings().m_MaxError;
 aFootprint->TransformFPShapesToPolySet( m_top_copper_shapes, F_Cu, 0, maxError, ERROR_INSIDE,
 false, /* include text */
 true, /* include shapes */
 false /* include private items */ );
 aFootprint->TransformFPShapesToPolySet( m_bottom_copper_shapes, B_Cu, 0, maxError, ERROR_INSIDE,
 false, /* include text */
 true, /* include shapes */
 false /* include private items */ );
 }
 
 if( ( !(aFootprint->GetAttributes() & (FP_THROUGH_HOLE|FP_SMD)) ) && !m_params.m_includeUnspecified )
 {
 return hasdata;
 }
 
 if( ( aFootprint->GetAttributes() & FP_DNP ) && !m_params.m_includeDNP )
 {
 return hasdata;
 }
 
 // Prefetch the library for this footprint
 // In case we need to resolve relative footprint paths
 wxString libraryName = aFootprint->GetFPID().GetLibNickname();
 wxString footprintBasePath = wxEmptyString;
 
 double posX = aFootprint->GetPosition().x - aOrigin.x;
 double posY = (aFootprint->GetPosition().y) - aOrigin.y;
 
 if( m_board->GetProject() )
 {
 try
 {
 // FindRow() can throw an exception
 const FP_LIB_TABLE_ROW* fpRow =
 m_board->GetProject()->PcbFootprintLibs()->FindRow( libraryName, false );
 
 if( fpRow )
 footprintBasePath = fpRow->GetFullURI( true );
 }
 catch( ... )
 {
 // Do nothing if the libraryName is not found in lib table
 }
 }
 
 // Exit early if we don't want to include footprint models
 if( m_params.m_boardOnly )
 {
 return hasdata;
 }
 
 VECTOR2D newpos( pcbIUScale.IUTomm( posX ), pcbIUScale.IUTomm( posY ) );
 
 for( const FP_3DMODEL& fp_model : aFootprint->Models() )
 {
 if( !fp_model.m_Show || fp_model.m_Filename.empty() )
 
 continue;
 
 std::vector<wxString> searchedPaths;
 wxString mname = m_resolver->ResolvePath( fp_model.m_Filename, footprintBasePath );
 
 
 if( !wxFileName::FileExists( mname ) )
 {
 ReportMessage( wxString::Format( wxT( "Could not add 3D model to %s.\n"
 "File not found: %s\n" ),
 aFootprint->GetReference(), mname ) );
 continue;
 }
 
 std::string fname( mname.ToUTF8() );
 std::string refName( aFootprint->GetReference().ToUTF8() );
 try
 {
 bool bottomSide = aFootprint->GetLayer() == B_Cu;
 
 // the rotation is stored in degrees but opencascade wants radians
 VECTOR3D modelRot = fp_model.m_Rotation;
 modelRot *= M_PI;
 modelRot /= 180.0;
 
 if( m_pcbModel->AddComponent( fname, refName, bottomSide,
 newpos,
 aFootprint->GetOrientation().AsRadians(),
 fp_model.m_Offset, modelRot,
 fp_model.m_Scale, m_params.m_substModels ) )
 {
 hasdata = true;
 }
 }
 catch( const Standard_Failure& e )
 {
 ReportMessage( wxString::Format( wxT( "Could not add 3D model to %s.\n"
  "OpenCASCADE error: %s\n" ),
 aFootprint->GetReference(), e.GetMessageString() ) );
 }
 
 }
 
 return hasdata;
}
 
 
bool EXPORTER_STEP::buildTrack3DShape( PCB_TRACK* aTrack, VECTOR2D aOrigin )
{
 if( aTrack->Type() == PCB_VIA_T )
 {
 PAD dummy( nullptr );
 int hole = static_cast<PCB_VIA*>( aTrack )->GetDrillValue();
 dummy.SetDrillSize( VECTOR2I( hole, hole ) );
 dummy.SetPosition( aTrack->GetStart() );
 dummy.SetSize( VECTOR2I( aTrack->GetWidth(), aTrack->GetWidth() ) );
 
 if( m_pcbModel->AddPadHole( &dummy, aOrigin ) )
 {
 if( m_pcbModel->AddPadShape( &dummy, aOrigin ) )
 return false;
 }
 
 return true;
 }
 
 PCB_LAYER_ID pcblayer = aTrack->GetLayer();
 
 if( pcblayer != F_Cu && pcblayer != B_Cu )
 return false;
 
 int maxError = m_board->GetDesignSettings().m_MaxError;
 
 if( pcblayer == F_Cu )
 aTrack->TransformShapeToPolygon( m_top_copper_shapes, pcblayer, 0, maxError, ERROR_INSIDE );
 else
 aTrack->TransformShapeToPolygon( m_bottom_copper_shapes, pcblayer, 0, maxError, ERROR_INSIDE );
 
 return true;
}
 
 
bool EXPORTER_STEP::buildGraphic3DShape( BOARD_ITEM* aItem, VECTOR2D aOrigin )
{
 PCB_SHAPE* graphic = dynamic_cast<PCB_SHAPE*>( aItem );
 
 if( ! graphic )
 return false;
 
 PCB_LAYER_ID pcblayer = graphic->GetLayer();
 
 if( pcblayer != F_Cu && pcblayer != B_Cu )
 return false;
 
 SHAPE_POLY_SET copper_shapes;
 int maxError = m_board->GetDesignSettings().m_MaxError;
 
 
 if( pcblayer == F_Cu )
 graphic->TransformShapeToPolygon( m_top_copper_shapes, pcblayer, 0,
 maxError, ERROR_INSIDE );
 else
 graphic->TransformShapeToPolygon( m_bottom_copper_shapes, pcblayer, 0,
 maxError, ERROR_INSIDE );
 
 return true;
}
 
 
bool EXPORTER_STEP::buildBoard3DShapes()
{
 if( m_pcbModel )
 return true;
 
 SHAPE_POLY_SET pcbOutlines; // stores the board main outlines
 
 if( !m_board->GetBoardPolygonOutlines( pcbOutlines,
 /* error handler */ nullptr,
 /* allows use arcs in outlines */ true ) )
 {
 wxLogWarning( _( "Board outline is malformed. Run DRC for a full analysis." ) );
 }
 
 VECTOR2D origin;
 
 // Determine the coordinate system reference:
 // Precedence of reference point is Drill Origin > Grid Origin > User Offset
 if( m_params.m_useDrillOrigin )
 origin = m_board->GetDesignSettings().GetAuxOrigin();
 else if( m_params.m_useGridOrigin )
 origin = m_board->GetDesignSettings().GetGridOrigin();
 else
 origin = m_params.m_origin;
 
 m_pcbModel = std::make_unique<STEP_PCB_MODEL>( m_pcbBaseName );
 
 // TODO: Handle when top & bottom soldermask colours are different...
 m_pcbModel->SetBoardColor( m_solderMaskColor.r, m_solderMaskColor.g, m_solderMaskColor.b );
 m_pcbModel->SetCopperColor( m_copperColor.r, m_copperColor.g, m_copperColor.b );
 
 m_pcbModel->SetPCBThickness( m_boardThickness );
 
 // Note: m_params.m_BoardOutlinesChainingEpsilon is used only to build the board outlines,
 // not to set OCC chaining epsilon (much smaller)
 //
 // Set the min distance between 2 points for OCC to see these 2 points as merged
 // OCC_MAX_DISTANCE_TO_MERGE_POINTS is acceptable for OCC, otherwise there are issues
 // to handle the shapes chaining on copper layers, because the Z dist is 0.035 mm and the
 // min dist must be much smaller (we use 0.001 mm giving good results)
 m_pcbModel->OCCSetMergeMaxDistance( OCC_MAX_DISTANCE_TO_MERGE_POINTS );
 
 m_pcbModel->SetMaxError( m_board->GetDesignSettings().m_MaxError );
 
 // For copper layers, only pads and tracks are added, because adding everything on copper
 // generate unreasonable file sizes and take a unreasonable calculation time.
 for( FOOTPRINT* fp : m_board->Footprints() )
 buildFootprint3DShapes( fp, origin );
 
 if( ExportTracksAndVias() )
 {
 for( PCB_TRACK* track : m_board->Tracks() )
 buildTrack3DShape( track, origin );
 
 for( BOARD_ITEM* item : m_board->Drawings() )
 buildGraphic3DShape( item, origin );
 }
 
 m_top_copper_shapes.Fracture( SHAPE_POLY_SET::PM_FAST );
 m_bottom_copper_shapes.Fracture( SHAPE_POLY_SET::PM_FAST );
 
 m_pcbModel->AddCopperPolygonShapes( &m_top_copper_shapes, true, origin );
 m_pcbModel->AddCopperPolygonShapes( &m_bottom_copper_shapes, false, origin );
 
 ReportMessage( wxT( "Create PCB solid model\n" ) );
 
 wxString msg;
 msg.Printf( wxT( "Board outline: find %d initial points\n" ), pcbOutlines.FullPointCount() );
 ReportMessage( msg );
 
 if( !m_pcbModel->CreatePCB( pcbOutlines, origin ) )
 {
 ReportMessage( wxT( "could not create PCB solid model\n" ) );
 return false;
 }
 
 return true;
}
 
 
void EXPORTER_STEP::calculatePcbThickness()
{
 m_boardThickness = DEFAULT_BOARD_THICKNESS_MM;
 
 const BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
 
 if( bds.GetStackupDescriptor().GetCount() )
 {
 int thickness = 0;
 
 for( BOARD_STACKUP_ITEM* item : bds.GetStackupDescriptor().GetList() )
 {
 switch( item->GetType() )
 {
 case BS_ITEM_TYPE_DIELECTRIC:
 // Dielectric can have sub-layers. Layer 0 is the main layer
 // Not frequent, but possible
 for( int idx = 0; idx < item->GetSublayersCount(); idx++ )
 thickness += item->GetThickness( idx );
 
 break;
 
 case BS_ITEM_TYPE_COPPER:
 if( item->IsEnabled() )
 thickness += item->GetThickness();
 
 break;
 
 default:
 break;
 }
 }
 
 if( thickness > 0 )
 m_boardThickness = pcbIUScale.IUTomm( thickness );
 }
}
 
 
bool EXPORTER_STEP::Export()
{
 // setup opencascade message log
 Message::DefaultMessenger()->RemovePrinters( STANDARD_TYPE( Message_PrinterOStream ) );
 Message::DefaultMessenger()->AddPrinter( new KiCadPrinter( this ) );
 
 ReportMessage( _( "Determining PCB data\n" ) );
 calculatePcbThickness();
 wxString msg;
 msg.Printf( _( "Board Thickness from stackup: %.3f mm\n" ), m_boardThickness );
 ReportMessage( msg );
 
 try
 {
 ReportMessage( _( "Build STEP data\n" ) );
 
 if( !buildBoard3DShapes() )
 {
 ReportMessage( _( "\n** Error building STEP board model. Export aborted. **\n" ) );
 return false;
 }
 
 ReportMessage( _( "Writing STEP file\n" ) );
 
 if( !m_pcbModel->WriteSTEP( m_outputFile ) )
 {
 ReportMessage( _( "\n** Error writing STEP file. **\n" ) );
 return false;
 }
 else
 {
 ReportMessage( wxString::Format( _( "\nSTEP file '%s' created.\n" ), m_outputFile ) );
 }
 }
 catch( const Standard_Failure& e )
 {
 ReportMessage( e.GetMessageString() );
 ReportMessage( _( "\n** Error exporting STEP file. Export aborted. **\n" ) );
 return false;
 }
 catch( ... )
 {
 ReportMessage( _( "\n** Error exporting STEP file. Export aborted. **\n" ) );
 return false;
 }
 
 if( m_fail || m_error )
 {
 if( m_fail )
 {
 msg = _( "Unable to create STEP file.\n"
 "Check that the board has a valid outline and models." );
 }
 else if( m_error || m_warn )
 {
 msg = _( "STEP file has been created, but there are warnings." );
 }
 
 ReportMessage( msg );
 }
 
 return true;
}