test_drc_solder_mask_expansion.cpp

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/*
 * This program source code file is part of KiCad, a free EDA CAD application.
 *
 * Copyright The 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, see <https://www.gnu.org/licenses/>.
 */
 
#include <qa_utils/wx_utils/unit_test_utils.h>
#include <pcbnew_utils/board_test_utils.h>
#include <board.h>
#include <board_design_settings.h>
#include <pad.h>
#include <pcb_track.h>
#include <pcb_shape.h>
#include <footprint.h>
#include <drc/drc_engine.h>
#include <core/profile.h>
#include <settings/settings_manager.h>
#include <drc/drc_item.h>
#include <widgets/report_severity.h>
 
 
struct DRC_SOLDER_MASK_EXPANSION_TEST_FIXTURE
{
    DRC_SOLDER_MASK_EXPANSION_TEST_FIXTURE()
    { }
 
    SETTINGS_MANAGER       m_settingsManager;
    std::unique_ptr<BOARD> m_board;
};
 
 
BOOST_FIXTURE_TEST_CASE( FootprintLevelSolderMaskExpansion, DRC_SOLDER_MASK_EXPANSION_TEST_FIXTURE )
{
    // This test verifies that footprint-level solder mask expansion override is correctly
    // applied to pads that don't have their own local override.
    // Regression test for https://gitlab.com/kicad/code/kicad/-/issues/22751
 
    KI_TEST::LoadBoard( m_settingsManager, "issue22751/issue22751", m_board );
 
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
    bds.m_DRCEngine->InitEngine( wxFileName() );
 
    // Board default solder mask expansion is 0.05mm (50000 IU)
    BOOST_CHECK_EQUAL( bds.m_SolderMaskExpansion, 50000 );
 
    // Find footprints and their pads
    PAD* padWithFootprintMargin = nullptr;
    PAD* padWithNoMargin = nullptr;
    PAD* padWithOwnMargin = nullptr;
 
    for( FOOTPRINT* fp : m_board->Footprints() )
    {
        if( fp->GetFPIDAsString() == "TestFootprint_WithSolderMaskMargin" )
        {
            // Footprint has solder mask margin of 0.1mm (100000 IU)
            BOOST_CHECK( fp->GetLocalSolderMaskMargin().has_value() );
            BOOST_CHECK_EQUAL( fp->GetLocalSolderMaskMargin().value(), 100000 );
 
            for( PAD* pad : fp->Pads() )
            {
                if( pad->GetNumber() == "1" )
                {
                    padWithFootprintMargin = pad;
 
                    // Pad should NOT have its own local margin
                    BOOST_CHECK( !pad->GetLocalSolderMaskMargin().has_value() );
                }
            }
        }
        else if( fp->GetFPIDAsString() == "TestFootprint_NoSolderMaskMargin" )
        {
            // Footprint has no solder mask margin
            BOOST_CHECK( !fp->GetLocalSolderMaskMargin().has_value() );
 
            for( PAD* pad : fp->Pads() )
            {
                if( pad->GetNumber() == "1" )
                    padWithNoMargin = pad;
            }
        }
        else if( fp->GetFPIDAsString() == "TestFootprint_PadOverridesSolderMaskMargin" )
        {
            // Footprint has solder mask margin of 0.1mm
            BOOST_CHECK( fp->GetLocalSolderMaskMargin().has_value() );
            BOOST_CHECK_EQUAL( fp->GetLocalSolderMaskMargin().value(), 100000 );
 
            for( PAD* pad : fp->Pads() )
            {
                if( pad->GetNumber() == "1" )
                {
                    padWithOwnMargin = pad;
 
                    // Pad has its own margin of 0.2mm (200000 IU)
                    BOOST_CHECK( pad->GetLocalSolderMaskMargin().has_value() );
                    BOOST_CHECK_EQUAL( pad->GetLocalSolderMaskMargin().value(), 200000 );
                }
            }
        }
    }
 
    BOOST_REQUIRE( padWithFootprintMargin != nullptr );
    BOOST_REQUIRE( padWithNoMargin != nullptr );
    BOOST_REQUIRE( padWithOwnMargin != nullptr );
 
    // Test GetSolderMaskExpansion which uses the DRC engine to evaluate the constraint
 
    // Pad in footprint with solder mask margin should use footprint's margin (0.1mm = 100000 IU)
    int expansionWithFpMargin = padWithFootprintMargin->GetSolderMaskExpansion( F_Mask );
    BOOST_CHECK_EQUAL( expansionWithFpMargin, 100000 );
 
    // Pad in footprint without solder mask margin should use board default (0.05mm = 50000 IU)
    int expansionNoMargin = padWithNoMargin->GetSolderMaskExpansion( F_Mask );
    BOOST_CHECK_EQUAL( expansionNoMargin, 50000 );
 
    // Pad with its own solder mask margin should use pad's margin (0.2mm = 200000 IU),
    // overriding the footprint's margin
    int expansionWithPadMargin = padWithOwnMargin->GetSolderMaskExpansion( F_Mask );
    BOOST_CHECK_EQUAL( expansionWithPadMargin, 200000 );
}
 
 
BOOST_FIXTURE_TEST_CASE( SolderMaskExpansionPerformance, DRC_SOLDER_MASK_EXPANSION_TEST_FIXTURE )
{
    // Verify that GetSolderMaskExpansion is fast when no custom DRC rules exist.
    // Regression test for https://gitlab.com/kicad/code/kicad/-/issues/23213
    //
    // Before the fix, GetSolderMaskExpansion called EvalRules for every item even when no
    // custom rules existed, causing a 10-14x DRC slowdown vs KiCad 9.
 
    KI_TEST::LoadBoard( m_settingsManager, "stonehenge", m_board );
 
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
    bds.m_DRCEngine->InitEngine( wxFileName() );
 
    BOOST_REQUIRE( !bds.m_DRCEngine->HasRulesForConstraintType( SOLDER_MASK_EXPANSION_CONSTRAINT ) );
 
    // Collect all items that would be queried during the solder mask test
    std::vector<PAD*>       pads;
    std::vector<PCB_TRACK*> tracks;
    std::vector<PCB_SHAPE*> shapes;
 
    for( FOOTPRINT* fp : m_board->Footprints() )
    {
        for( PAD* pad : fp->Pads() )
            pads.push_back( pad );
 
        for( BOARD_ITEM* item : fp->GraphicalItems() )
        {
            if( item->Type() == PCB_SHAPE_T )
                shapes.push_back( static_cast<PCB_SHAPE*>( item ) );
        }
    }
 
    for( PCB_TRACK* track : m_board->Tracks() )
        tracks.push_back( track );
 
    for( BOARD_ITEM* item : m_board->Drawings() )
    {
        if( item->Type() == PCB_SHAPE_T )
            shapes.push_back( static_cast<PCB_SHAPE*>( item ) );
    }
 
    // Simulate the access pattern from the solder mask bridge test: call GetSolderMaskExpansion
    // many times for each item (once per potential collision pair).
    const int iterations = 1000;
 
    PROF_TIMER timer;
 
    for( int i = 0; i < iterations; ++i )
    {
        for( PAD* pad : pads )
            pad->GetSolderMaskExpansion( F_Mask );
 
        for( PCB_TRACK* track : tracks )
            track->GetSolderMaskExpansion();
 
        for( PCB_SHAPE* shape : shapes )
            shape->GetSolderMaskExpansion();
    }
 
    timer.Stop();
 
    int totalCalls = iterations * ( pads.size() + tracks.size() + shapes.size() );
 
    BOOST_TEST_MESSAGE( wxString::Format( "%d calls to GetSolderMaskExpansion took %0.1f ms "
                                          "(%0.0f ns/call)",
                                          totalCalls, timer.msecs(),
                                          timer.msecs() * 1e6 / totalCalls ) );
 
    // Sanitizer instrumentation changes execution cost, not the lookup contract
#if !defined( KICAD_SANITIZE_THREADS ) && !defined( KICAD_SANITIZE_ADDRESS )
    // With the fix (direct property lookup), this should be well under 100ms.
    // Without the fix (EvalRules for every call), this was ~500ms+ even in debug builds.
    // Use a generous threshold to avoid flakiness on slow CI machines.
    BOOST_CHECK_MESSAGE( timer.msecs() < 500.0,
                         wxString::Format( "GetSolderMaskExpansion too slow: %0.1f ms for %d calls",
                                           timer.msecs(), totalCalls ) );
#endif
}
 
 
struct SILK_MASK_EXPANSION_FIXTURE
{
    SILK_MASK_EXPANSION_FIXTURE() :
            m_board( std::make_unique<BOARD>() )
    {
        BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
 
        bds.m_SolderMaskExpansion = pcbIUScale.mmToIU( 0.1 );
        bds.m_SolderMaskMinWidth = 0;
        bds.m_TentViasFront = false;
        bds.m_TentViasBack = false;
 
        FOOTPRINT* footprint = new FOOTPRINT( m_board.get() );
        m_board->Add( footprint );
 
        PAD* pad = new PAD( footprint );
        pad->SetAttribute( PAD_ATTRIB::PTH );
        pad->SetShape( PADSTACK::ALL_LAYERS, PAD_SHAPE::CIRCLE );
        pad->SetSize( PADSTACK::ALL_LAYERS, VECTOR2I( pcbIUScale.mmToIU( 1.0 ), pcbIUScale.mmToIU( 1.0 ) ) );
        pad->SetPrimaryDrillSize( VECTOR2I( pcbIUScale.mmToIU( 0.5 ), pcbIUScale.mmToIU( 0.5 ) ) );
        pad->SetLayerSet( LSET( { F_Cu, B_Cu, F_Mask, B_Mask } ) );
        pad->SetPosition( VECTOR2I( 0, 0 ) );
        footprint->Add( pad );
 
        PCB_VIA* via = new PCB_VIA( m_board.get() );
        via->SetLayerPair( F_Cu, B_Cu );
        via->SetPosition( VECTOR2I( pcbIUScale.mmToIU( 10.0 ), 0 ) );
        via->SetWidth( PADSTACK::ALL_LAYERS, pcbIUScale.mmToIU( 0.8 ) );
        via->SetDrill( pcbIUScale.mmToIU( 0.4 ) );
        m_board->Add( via );
 
        m_board->BuildConnectivity();
 
        std::shared_ptr<DRC_ENGINE> engine = std::make_shared<DRC_ENGINE>( m_board.get(), &bds );
        engine->InitEngine( wxFileName() );
        bds.m_DRCEngine = engine;
    }
 
    void AddSilkLine( double aFromMM, double aToMM, double aOffsetMM )
    {
        PCB_SHAPE* line = new PCB_SHAPE( m_board.get(), SHAPE_T::SEGMENT );
        int        y = pcbIUScale.mmToIU( aOffsetMM );
 
        line->SetLayer( F_SilkS );
        line->SetStart( VECTOR2I( pcbIUScale.mmToIU( aFromMM ), y ) );
        line->SetEnd( VECTOR2I( pcbIUScale.mmToIU( aToMM ), y ) );
        line->SetWidth( pcbIUScale.mmToIU( 0.15 ) );
        m_board->Add( line );
    }
 
    int CountMaskViolations()
    {
        BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
        int                    count = 0;
 
        for( int code = 0; code < DRCE_LAST; ++code )
            bds.m_DRCSeverities[code] = SEVERITY::RPT_SEVERITY_IGNORE;
 
        bds.m_DRCSeverities[DRCE_SILK_MASK_CLEARANCE] = SEVERITY::RPT_SEVERITY_ERROR;
 
        bds.m_DRCEngine->SetViolationHandler(
                [&]( const std::shared_ptr<DRC_ITEM>& aItem, const VECTOR2I&, int,
                     const std::function<void( PCB_MARKER* )>& )
                {
                    if( aItem->GetErrorCode() == DRCE_SILK_MASK_CLEARANCE )
                        ++count;
                } );
 
        bds.m_DRCEngine->RunTests( EDA_UNITS::MM, true, false );
        bds.m_DRCEngine->ClearViolationHandler();
 
        return count;
    }
 
    std::unique_ptr<BOARD> m_board;
};
 
 
BOOST_FIXTURE_TEST_CASE( SilkInsideViaMaskOpeningIsReported, SILK_MASK_EXPANSION_FIXTURE )
{
    AddSilkLine( 8.0, 12.0, -0.525 );
 
    BOOST_CHECK_MESSAGE( CountMaskViolations() == 1, "silk clear of the via copper but inside its mask opening was not "
                                                     "reported" );
}
 
 
BOOST_FIXTURE_TEST_CASE( SilkInsidePadMaskOpeningIsReported, SILK_MASK_EXPANSION_FIXTURE )
{
    AddSilkLine( -2.0, 2.0, -0.625 );
 
    BOOST_CHECK_MESSAGE( CountMaskViolations() == 1, "silk clear of the pad copper but inside its mask opening was not "
                                                     "reported" );
}
 
 
BOOST_FIXTURE_TEST_CASE( SilkOutsidePadMaskOpeningIsNotReported, SILK_MASK_EXPANSION_FIXTURE )
{
    AddSilkLine( -2.0, 2.0, 0.75 );
 
    BOOST_CHECK_MESSAGE( CountMaskViolations() == 0, "silk clear of the pad mask opening was reported" );
}