test_zone_filler.cpp

Go to the documentation of this file.

/*
 * 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 <boost/test/data/test_case.hpp>
 
#include <chrono>
#include <cmath>
 
#include <pcbnew_utils/board_test_utils.h>
#include <board.h>
#include <board_commit.h>
#include <wx/log.h>
#include <zone_filler.h>
#include <board_design_settings.h>
#include <drc/drc_engine.h>
#include <pad.h>
#include <pcb_track.h>
#include <footprint.h>
#include <zone.h>
#include <drc/drc_engine.h>
#include <drc/drc_item.h>
#include <settings/settings_manager.h>
#include <geometry/shape_poly_set.h>
#include <advanced_config.h>
#include <connectivity/connectivity_data.h>
#include <teardrop/teardrop.h>
#include <project/net_settings.h>
#include <netclass.h>
#include <netinfo.h>
 

static void CheckAllOutlineAreasAtLeast( const std::shared_ptr<SHAPE_POLY_SET>& aFill,
                                         double aMinArea, const wxString& aLabel )
{
    for( int ii = 0; ii < aFill->OutlineCount(); ++ii )
    {
        const double area = std::abs( aFill->Outline( ii ).Area() );
 
        BOOST_CHECK_MESSAGE( area >= aMinArea,
                             wxString::Format( "%s %d area %.0f IU^2 below %.0f IU^2; partial "
                                               "stamps should not survive.",
                                               aLabel, ii, area, aMinArea ) );
    }
}
 
 
struct ZONE_FILL_TEST_FIXTURE
{
    ZONE_FILL_TEST_FIXTURE()
    { }
 
    SETTINGS_MANAGER       m_settingsManager;
    std::unique_ptr<BOARD> m_board;
};
 
 
int delta = KiROUND( 0.006 * pcbIUScale.IU_PER_MM );
 
 
BOOST_FIXTURE_TEST_CASE( BasicZoneFills, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "zone_filler", m_board );
 
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
 
    KI_TEST::FillZones( m_board.get() );
 
    // Now that the zones are filled we're going to increase the size of -some- pads and
    // tracks so that they generate DRC errors.  The test then makes sure that those errors
    // are generated, and that the other pads and tracks do -not- generate errors.
 
    for( PAD* pad : m_board->Footprints()[0]->Pads() )
    {
        if( pad->GetNumber() == "2" || pad->GetNumber() == "4" || pad->GetNumber() == "6" )
            pad->SetSize( PADSTACK::ALL_LAYERS, pad->GetSize( PADSTACK::ALL_LAYERS ) + VECTOR2I( delta, delta ) );
    }
 
    int  ii = 0;
    KIID arc8;
    KIID arc12;
 
    for( PCB_TRACK* track : m_board->Tracks() )
    {
        if( track->Type() == PCB_ARC_T )
        {
            ii++;
 
            if( ii == 8 )
            {
                arc8 = track->m_Uuid;
                track->SetWidth( track->GetWidth() + delta + delta );
            }
            else if( ii == 12 )
            {
                arc12 = track->m_Uuid;
                track->Move( VECTOR2I( -delta, -delta ) );
            }
        }
    }
 
    bool foundPad2Error = false;
    bool foundPad4Error = false;
    bool foundPad6Error = false;
    bool foundArc8Error = false;
    bool foundArc12Error = false;
    bool foundOtherError = false;
 
    bds.m_DRCEngine->InitEngine( wxFileName() );     // Just to be sure to be sure
 
    bds.m_DRCEngine->SetViolationHandler(
            [&]( const std::shared_ptr<DRC_ITEM>& aItem, const VECTOR2I& aPos, int aLayer,
                 const std::function<void( PCB_MARKER* )>& aPathGenerator )
            {
                if( aItem->GetErrorCode() == DRCE_CLEARANCE )
                {
                    BOARD_ITEM* item_a = m_board->ResolveItem( aItem->GetMainItemID() );
                    PAD*        pad_a = dynamic_cast<PAD*>( item_a );
                    PCB_TRACK*  trk_a = dynamic_cast<PCB_TRACK*>( item_a );
 
                    BOARD_ITEM* item_b = m_board->ResolveItem( aItem->GetAuxItemID() );
                    PAD*        pad_b = dynamic_cast<PAD*>( item_b );
                    PCB_TRACK*  trk_b = dynamic_cast<PCB_TRACK*>( item_b );
 
                    if(      pad_a && pad_a->GetNumber() == "2" ) foundPad2Error = true;
                    else if( pad_a && pad_a->GetNumber() == "4" ) foundPad4Error = true;
                    else if( pad_a && pad_a->GetNumber() == "6" ) foundPad6Error = true;
                    else if( pad_b && pad_b->GetNumber() == "2" ) foundPad2Error = true;
                    else if( pad_b && pad_b->GetNumber() == "4" ) foundPad4Error = true;
                    else if( pad_b && pad_b->GetNumber() == "6" ) foundPad6Error = true;
                    else if( trk_a && trk_a->m_Uuid == arc8 )     foundArc8Error = true;
                    else if( trk_a && trk_a->m_Uuid == arc12 )    foundArc12Error = true;
                    else if( trk_b && trk_b->m_Uuid == arc8 )     foundArc8Error = true;
                    else if( trk_b && trk_b->m_Uuid == arc12 )    foundArc12Error = true;
                    else                                          foundOtherError = true;
 
                }
            } );
 
    bds.m_DRCEngine->RunTests( EDA_UNITS::MM, true, false );
 
    BOOST_CHECK_EQUAL( foundPad2Error, true );
    BOOST_CHECK_EQUAL( foundPad4Error, true );
    BOOST_CHECK_EQUAL( foundPad6Error, true );
    BOOST_CHECK_EQUAL( foundArc8Error, true );
    BOOST_CHECK_EQUAL( foundArc12Error, true );
    BOOST_CHECK_EQUAL( foundOtherError, false );
}
 
 
BOOST_FIXTURE_TEST_CASE( NotchedZones, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "notched_zones", m_board );
 
    // Older algorithms had trouble where the filleted zones intersected and left notches.
    // See:
    //   https://gitlab.com/kicad/code/kicad/-/issues/2737
    //   https://gitlab.com/kicad/code/kicad/-/issues/2752
    SHAPE_POLY_SET frontCopper;
 
    KI_TEST::FillZones( m_board.get() );
 
    frontCopper = SHAPE_POLY_SET();
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( zone->GetLayerSet().Contains( F_Cu ) )
        {
            frontCopper.BooleanAdd( *zone->GetFilledPolysList( F_Cu ) );
        }
    }
 
    BOOST_CHECK_EQUAL( frontCopper.OutlineCount(), 2 );
}
 
 
static const std::vector<wxString> RegressionZoneFillTests_tests = {
    "issue18",
    "issue2568",
    "issue3812",
    "issue5102",
    "issue5313",
    "issue5320",
    "issue5567",
    "issue5830",
    "issue6039",
    "issue6260",
    "issue6284",
    "issue7086",
    "issue14294",   // Bad Clipper2 fill
    "fill_bad"      // Missing zone clearance expansion
};
 
 
BOOST_DATA_TEST_CASE_F( ZONE_FILL_TEST_FIXTURE, RegressionZoneFillTests,
                        boost::unit_test::data::make( RegressionZoneFillTests_tests ), relPath )
{
    KI_TEST::LoadBoard( m_settingsManager, relPath, m_board );
 
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
 
    KI_TEST::FillZones( m_board.get() );
 
    std::vector<DRC_ITEM> violations;
 
    bds.m_DRCEngine->SetViolationHandler(
            [&]( const std::shared_ptr<DRC_ITEM>& aItem, const VECTOR2I& aPos, int aLayer,
                 const std::function<void( PCB_MARKER* )>& aPathGenerator )
            {
                if( aItem->GetErrorCode() == DRCE_CLEARANCE )
                    violations.push_back( *aItem );
            } );
 
    bds.m_DRCEngine->RunTests( EDA_UNITS::MM, true, false );
 
    if( violations.empty() )
    {
        BOOST_CHECK_EQUAL( 1, 1 );  // quiet "did not check any assertions" warning
        BOOST_TEST_MESSAGE( wxString::Format( "Zone fill regression: %s passed", relPath ) );
    }
    else
    {
        UNITS_PROVIDER unitsProvider( pcbIUScale, EDA_UNITS::INCH );
 
        BOARD_RC_ITEM_RESOLVER resolver( *m_board );
 
        for( const DRC_ITEM& item : violations )
            BOOST_TEST_MESSAGE( item.ShowReport( &unitsProvider, RPT_SEVERITY_ERROR, resolver ) );
 
        BOOST_ERROR( wxString::Format( "Zone fill regression: %s failed", relPath ) );
    }
}
 
 
BOOST_FIXTURE_TEST_CASE( ZoneFillClearsLineEndings, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "line_ending_zone_flood/line_ending_zone_flood", m_board );
 
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
 
    KI_TEST::FillZones( m_board.get() );
 
    std::vector<DRC_ITEM> violations;
 
    bds.m_DRCEngine->SetViolationHandler(
            [&]( const std::shared_ptr<DRC_ITEM>& aItem, const VECTOR2I&, int,
                 const std::function<void( PCB_MARKER* )>& )
            {
                if( aItem->GetErrorCode() == DRCE_CLEARANCE || aItem->GetErrorCode() == DRCE_SHORTING_ITEMS )
                {
                    violations.push_back( *aItem );
                }
            } );
 
    bds.m_DRCEngine->RunTests( EDA_UNITS::MM, true, false );
    bds.m_DRCEngine->ClearViolationHandler();
 
    if( violations.empty() )
    {
        BOOST_CHECK_EQUAL( violations.size(), 0 );
        return;
    }
 
    UNITS_PROVIDER            unitsProvider( pcbIUScale, EDA_UNITS::INCH );
    BOARD_RC_ITEM_RESOLVER    resolver( *m_board );
 
    for( const DRC_ITEM& item : violations )
        BOOST_TEST_MESSAGE( item.ShowReport( &unitsProvider, RPT_SEVERITY_ERROR, resolver ) );
 
    BOOST_ERROR( wxString::Format( "Zone fill line-ending regression failed with %d clearance/shorting violations",
                                   (int) violations.size() ) );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionZoneClearanceWithIterativeRefill, ZONE_FILL_TEST_FIXTURE )
{
    ADVANCED_CFG& cfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
    bool          originalIterativeRefill = cfg.m_ZoneFillIterativeRefill;
 
    struct ScopeGuard
    {
        bool& ref;
        bool  orig;
        ~ScopeGuard() { ref = orig; }
    } guard{ cfg.m_ZoneFillIterativeRefill, originalIterativeRefill };
 
    auto runDrcClearanceCheck =
            [this]( bool aIterative ) -> int
            {
                ADVANCED_CFG& innerCfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
                innerCfg.m_ZoneFillIterativeRefill = aIterative;
 
                KI_TEST::LoadBoard( m_settingsManager, "issue23053/issue23053", m_board );
 
                BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
 
                KI_TEST::FillZones( m_board.get() );
 
                std::vector<DRC_ITEM> violations;
 
                BOARD_RC_ITEM_RESOLVER resolver( *m_board );
                UNITS_PROVIDER unitsProvider( pcbIUScale, EDA_UNITS::MM );
 
                bds.m_DRCEngine->SetViolationHandler(
                        [&]( const std::shared_ptr<DRC_ITEM>& aItem, const VECTOR2I& aPos, int aLayer,
                             const std::function<void( PCB_MARKER* )>& aPathGenerator )
                        {
                            if( aItem->GetErrorCode() == DRCE_CLEARANCE )
                            {
                                BOARD_ITEM* itemA = m_board->ResolveItem( aItem->GetMainItemID() );
                                BOARD_ITEM* itemB = m_board->ResolveItem( aItem->GetAuxItemID() );
 
                                if( dynamic_cast<ZONE*>( itemA ) && dynamic_cast<ZONE*>( itemB ) )
                                {
                                    violations.push_back( *aItem );
 
                                    BOOST_TEST_MESSAGE( aItem->ShowReport( &unitsProvider, RPT_SEVERITY_ERROR,
                                                                           resolver ) );
                                }
                            }
                        } );
 
                bds.m_DRCEngine->RunTests( EDA_UNITS::MM, true, false );
 
                return static_cast<int>( violations.size() );
            };
 
    int iterativeViolations = runDrcClearanceCheck( true );
 
    BOOST_CHECK_MESSAGE( iterativeViolations == 0,
                         wxString::Format( "Iterative refill produced %d zone-to-zone clearance "
                                           "violations (expected 0)", iterativeViolations ) );
 
    int nonIterativeViolations = runDrcClearanceCheck( false );
 
    BOOST_CHECK_MESSAGE( nonIterativeViolations == 0,
                         wxString::Format( "Non-iterative refill produced %d zone-to-zone clearance "
                                           "violations (expected 0)", nonIterativeViolations ) );
}
 
 
static const std::vector<wxString> RegressionSliverZoneFillTests_tests = {
    "issue16182"    // Slivers
};
 
 
BOOST_DATA_TEST_CASE_F( ZONE_FILL_TEST_FIXTURE, RegressionSliverZoneFillTests,
                        boost::unit_test::data::make( RegressionSliverZoneFillTests_tests ), relPath )
{
    KI_TEST::LoadBoard( m_settingsManager, relPath, m_board );
 
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
 
    KI_TEST::FillZones( m_board.get() );
 
    std::vector<DRC_ITEM> violations;
 
    bds.m_DRCEngine->SetViolationHandler(
            [&]( const std::shared_ptr<DRC_ITEM>& aItem, const VECTOR2I& aPos, int aLayer,
                 const std::function<void( PCB_MARKER* )>& aPathGenerator )
            {
                if( aItem->GetErrorCode() == DRCE_COPPER_SLIVER )
                    violations.push_back( *aItem );
            } );
 
    bds.m_DRCEngine->RunTests( EDA_UNITS::MM, true, false );
 
    if( violations.empty() )
    {
        BOOST_CHECK_EQUAL( 1, 1 );  // quiet "did not check any assertions" warning
        BOOST_TEST_MESSAGE( wxString::Format( "Zone fill copper sliver regression: %s passed", relPath ) );
    }
    else
    {
        UNITS_PROVIDER unitsProvider( pcbIUScale, EDA_UNITS::INCH );
 
        BOARD_RC_ITEM_RESOLVER resolver( *m_board );
 
        for( const DRC_ITEM& item : violations )
            BOOST_TEST_MESSAGE( item.ShowReport( &unitsProvider, RPT_SEVERITY_ERROR, resolver ) );
 
        BOOST_ERROR( wxString::Format( "Zone fill copper sliver regression: %s failed", relPath ) );
    }
}
 
 
static const std::vector<std::pair<wxString,int>> RegressionTeardropFill_tests = {
        { "teardrop_issue_JPC2", 5 },    // Arcs with teardrops connecting to pads
};
 
 
BOOST_DATA_TEST_CASE_F( ZONE_FILL_TEST_FIXTURE, RegressionTeardropFill,
                        boost::unit_test::data::make( RegressionTeardropFill_tests ), test )
{
    const wxString& relPath = test.first;
    const int count = test.second;
 
    KI_TEST::LoadBoard( m_settingsManager, relPath, m_board );
    KI_TEST::FillZones( m_board.get() );
 
    int zoneCount = 0;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( zone->IsTeardropArea() )
            zoneCount++;
    }
 
    BOOST_CHECK_MESSAGE( zoneCount == count, "Expected " << count << " teardrop zones in " << relPath << ", found "
                                                         << zoneCount );
}
 
 
BOOST_FIXTURE_TEST_CASE( RegressionNetTie, ZONE_FILL_TEST_FIXTURE )
{
 
    std::vector<wxString> tests = { { "issue19956/issue19956" }    // Arcs with teardrops connecting to pads
                                  };
 
    for( const wxString& relPath : tests )
    {
        KI_TEST::LoadBoard( m_settingsManager, relPath, m_board );
        KI_TEST::FillZones( m_board.get() );
 
        for( ZONE* zone : m_board->Zones() )
        {
            for( PCB_LAYER_ID layer : zone->GetLayerSet() )
            {
                std::shared_ptr<SHAPE> a_shape( zone->GetEffectiveShape( layer ) );
 
                for( PAD* pad : m_board->GetPads() )
                {
                    std::shared_ptr<SHAPE> pad_shape( pad->GetEffectiveShape( layer ) );
                    int                    clearance = pad_shape->GetClearance( a_shape.get() );
                    BOOST_CHECK_MESSAGE( pad->GetNetCode() == zone->GetNetCode() || clearance != 0,
                                         wxString::Format( "Pad %s from Footprint %s has net code %s and "
                                                           "is connected to zone with net code %s",
                                                           pad->GetNumber(),
                                                           pad->GetParentFootprint()->GetReferenceAsString(),
                                                           pad->GetNetname(),
                                                           zone->GetNetname() ) );
                }
            }
        }
    }
}
 

BOOST_FIXTURE_TEST_CASE( RegressionZonePriorityIsolatedIslands, ZONE_FILL_TEST_FIXTURE )
{
    // Enable iterative refill to fix issue 21746
    ADVANCED_CFG& cfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
    bool          originalIterativeRefill = cfg.m_ZoneFillIterativeRefill;
    cfg.m_ZoneFillIterativeRefill = true;
 
    // Restore config at end of scope to avoid polluting other tests
    struct ScopeGuard
    {
        bool& ref;
        bool  orig;
        ~ScopeGuard() { ref = orig; }
    } guard{ cfg.m_ZoneFillIterativeRefill, originalIterativeRefill };
 
    KI_TEST::LoadBoard( m_settingsManager, "issue21746/issue21746", m_board );
 
    KI_TEST::FillZones( m_board.get() );
 
    // Find the GND zone
    ZONE* gndZone = nullptr;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( zone->GetNetname() == "GND" )
        {
            gndZone = zone;
            break;
        }
    }
 
    BOOST_REQUIRE_MESSAGE( gndZone != nullptr, "GND zone not found in test board" );
 
    // Calculate board outline area
    SHAPE_POLY_SET boardOutline;
    bool hasOutline = m_board->GetBoardPolygonOutlines( boardOutline, true );
    BOOST_REQUIRE_MESSAGE( hasOutline, "Board outline not found" );
 
    double boardArea = 0.0;
 
    for( int i = 0; i < boardOutline.OutlineCount(); i++ )
        boardArea += boardOutline.Outline( i ).Area();
 
    // Get GND zone filled area
    gndZone->CalculateFilledArea();
    double gndFilledArea = gndZone->GetFilledArea();
 
    // The GND zone should fill at least 25% of the board area
    // With the bug, it fills almost nothing because VDD knocks it out
    double fillRatio = gndFilledArea / boardArea;
 
    BOOST_TEST_MESSAGE( wxString::Format( "Board area: %.2f sq mm, GND filled area: %.2f sq mm, Fill ratio: %.1f%%",
                                          boardArea / 1e6,
                                          gndFilledArea / 1e6,
                                          fillRatio * 100.0 ) );
 
    BOOST_CHECK_MESSAGE( fillRatio >= 0.25,
                         wxString::Format( "GND zone fill ratio %.1f%% is less than expected 25%%. This indicates "
                                           "issue 21746 - lower priority zones not filling areas where higher "
                                           "priority isolated islands were removed.",
                                           fillRatio * 100.0 ) );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionViaFlashingUnreachableZone, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue22010/issue22010", m_board );
 
    KI_TEST::FillZones( m_board.get() );
 
    // Find vias with zone_layer_connections set for In1.Cu or In2.Cu
    // After filling, vias that the zone doesn't actually reach should NOT be flashed
    int viasWithUnreachableFlashing = 0;
    int totalConditionalVias = 0;
 
    PCB_LAYER_ID in1Cu = m_board->GetLayerID( wxT( "In1.Cu" ) );
    PCB_LAYER_ID in2Cu = m_board->GetLayerID( wxT( "In2.Cu" ) );
 
    for( PCB_TRACK* track : m_board->Tracks() )
    {
        if( track->Type() != PCB_VIA_T )
            continue;
 
        PCB_VIA* via = static_cast<PCB_VIA*>( track );
 
        if( !via->GetRemoveUnconnected() )
            continue;
 
        totalConditionalVias++;
 
        // Check if via is flashed on In1.Cu or In2.Cu
        bool flashedOnIn1 = via->FlashLayer( in1Cu );
        bool flashedOnIn2 = via->FlashLayer( in2Cu );
 
        if( !flashedOnIn1 && !flashedOnIn2 )
            continue;
 
        VECTOR2I viaCenter = via->GetPosition();
        int      holeRadius = via->GetDrillValue() / 2;
 
        // Check if any zone fill actually reaches this via
        bool zoneReachesVia = false;
 
        for( ZONE* zone : m_board->Zones() )
        {
            if( zone->GetIsRuleArea() )
                continue;
 
            if( zone->GetNetCode() != via->GetNetCode() )
                continue;
 
            for( PCB_LAYER_ID layer : { in1Cu, in2Cu } )
            {
                if( !zone->IsOnLayer( layer ) )
                    continue;
 
                if( !zone->HasFilledPolysForLayer( layer ) )
                    continue;
 
                const std::shared_ptr<SHAPE_POLY_SET>& fill = zone->GetFilledPolysList( layer );
 
                if( fill->Contains( viaCenter, -1, holeRadius ) )
                {
                    zoneReachesVia = true;
                    break;
                }
            }
 
            if( zoneReachesVia )
                break;
        }
 
        // If via is flashed but zone doesn't reach it, that's the bug
        if( !zoneReachesVia && ( flashedOnIn1 || flashedOnIn2 ) )
            viasWithUnreachableFlashing++;
    }
 
    BOOST_TEST_MESSAGE( wxString::Format( "Total conditional vias: %d, Vias with unreachable flashing: %d",
                                          totalConditionalVias,
                                          viasWithUnreachableFlashing ) );
 
    BOOST_CHECK_MESSAGE( viasWithUnreachableFlashing == 0,
                         wxString::Format( "Found %d vias flashed on zone layers where the zone fill doesn't "
                                           "actually reach them. This indicates issue 22010 is not fixed.",
                                           viasWithUnreachableFlashing ) );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionViaZoneNetShort, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue12964/issue12964", m_board );
 
    KI_TEST::FillZones( m_board.get() );
 
    int viasShortingZones = 0;
    int totalConditionalVias = 0;
 
    for( PCB_TRACK* track : m_board->Tracks() )
    {
        if( track->Type() != PCB_VIA_T )
            continue;
 
        PCB_VIA* via = static_cast<PCB_VIA*>( track );
 
        if( !via->GetRemoveUnconnected() )
            continue;
 
        totalConditionalVias++;
 
        VECTOR2I viaCenter = via->GetPosition();
 
        for( ZONE* zone : m_board->Zones() )
        {
            if( zone->GetIsRuleArea() )
                continue;
 
            if( zone->GetNetCode() == via->GetNetCode() )
                continue;
 
            for( PCB_LAYER_ID layer : zone->GetLayerSet().Seq() )
            {
                if( !via->FlashLayer( layer ) )
                    continue;
 
                if( !zone->HasFilledPolysForLayer( layer ) )
                    continue;
 
                const std::shared_ptr<SHAPE_POLY_SET>& fill = zone->GetFilledPolysList( layer );
                int viaRadius = via->GetWidth( layer ) / 2;
 
                if( fill->Contains( viaCenter, -1, viaRadius ) )
                {
                    BOOST_TEST_MESSAGE( wxString::Format( "Via at (%d, %d) on net %s is flashing on layer %s where "
                                                          "zone net %s is filled - this creates a short!",
                                                          viaCenter.x, viaCenter.y,
                                                          via->GetNetname(),
                                                          m_board->GetLayerName( layer ),
                                                          zone->GetNetname() ) );
                    viasShortingZones++;
                }
            }
        }
    }
 
    BOOST_TEST_MESSAGE( wxString::Format( "Total conditional vias: %d, Vias shorting zones: %d",
                                          totalConditionalVias,
                                          viasShortingZones ) );
 
    BOOST_CHECK_MESSAGE( viasShortingZones == 0,
                         wxString::Format( "Found %d vias flashed on layers where they short to zones with "
                                           "different nets. This indicates issue 12964 is not fixed.",
                                           viasShortingZones ) );
}
 

BOOST_FIXTURE_TEST_CASE( HatchZoneThermalConnectivity, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "hatch_thermal_connectivity/hatch_thermal_connectivity",
                        m_board );
 
    KI_TEST::FillZones( m_board.get() );
 
    m_board->BuildConnectivity();
 
    int unconnectedCount = m_board->GetConnectivity()->GetUnconnectedCount( false );
 
    BOOST_CHECK_MESSAGE( unconnectedCount == 0,
                         wxString::Format( "Found %d unconnected items after zone fill. Hatch zone thermal "
                                           "reliefs should maintain connectivity even with large hatch gaps.",
                                           unconnectedCount ) );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionShallowArcZoneFill, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue22475/issue22475", m_board );
 
    PCB_LAYER_ID in1Cu = m_board->GetLayerID( wxT( "In1.Cu" ) );
 
    ZONE* gndZone = nullptr;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( zone->GetNetname() == "GND" && zone->IsOnLayer( in1Cu ) )
        {
            gndZone = zone;
            break;
        }
    }
 
    BOOST_REQUIRE_MESSAGE( gndZone != nullptr, "GND zone on In1.Cu not found in test board" );
 
    if( !gndZone )
        return;
 
    KI_TEST::FillZones( m_board.get() );
 
    BOOST_REQUIRE_MESSAGE( gndZone->HasFilledPolysForLayer( in1Cu ), "GND zone has no fill on In1.Cu" );
 
    const std::shared_ptr<SHAPE_POLY_SET>& fill = gndZone->GetFilledPolysList( in1Cu );
 
    // The zone fill should produce a single contiguous outline. Multiple outlines
    // indicate disconnected fill areas caused by malformed clearance holes.
    BOOST_CHECK_EQUAL( fill->OutlineCount(), 1 );
 
    double zoneOutlineArea = gndZone->Outline()->Area();
 
    BOOST_REQUIRE_MESSAGE( zoneOutlineArea > 0.0, "Zone outline area must be positive" );
 
    double fillArea = 0.0;
 
    for( int i = 0; i < fill->OutlineCount(); i++ )
        fillArea += std::abs( fill->Outline( i ).Area() );
 
    double fillRatio = fillArea / zoneOutlineArea;
 
    // The zone should be mostly filled. A low fill ratio indicates excessive voids
    // from malformed clearance holes around shallow arcs.
    BOOST_CHECK_GE( fillRatio, 0.90 );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionIterativeRefillRespectsKeepouts, ZONE_FILL_TEST_FIXTURE )
{
    // Enable iterative refill
    ADVANCED_CFG& cfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
    bool          originalIterativeRefill = cfg.m_ZoneFillIterativeRefill;
    cfg.m_ZoneFillIterativeRefill = true;
 
    struct ScopeGuard
    {
        bool& ref;
        bool orig;
        ~ScopeGuard() { ref = orig; }
    } guard{ cfg.m_ZoneFillIterativeRefill, originalIterativeRefill };
 
    KI_TEST::LoadBoard( m_settingsManager, "issue22809/issue22809", m_board );
 
    KI_TEST::FillZones( m_board.get() );
 
    // Find all zone keepouts
    std::vector<ZONE*> keepouts;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( zone->GetIsRuleArea() && zone->GetDoNotAllowZoneFills() )
            keepouts.push_back( zone );
    }
 
    BOOST_REQUIRE_MESSAGE( !keepouts.empty(), "No zone keepouts found in test board" );
 
    // For each keepout, check that no zone fill exists inside it
    int violationCount = 0;
 
    for( ZONE* keepout : keepouts )
    {
        for( PCB_LAYER_ID layer : keepout->GetLayerSet().Seq() )
        {
            SHAPE_POLY_SET keepoutOutline( *keepout->Outline() );
            keepoutOutline.ClearArcs();
 
            for( ZONE* zone : m_board->Zones() )
            {
                if( zone->GetIsRuleArea() )
                    continue;
 
                if( !zone->IsOnLayer( layer ) )
                    continue;
 
                if( !zone->HasFilledPolysForLayer( layer ) )
                    continue;
 
                const std::shared_ptr<SHAPE_POLY_SET>& fill = zone->GetFilledPolysList( layer );
 
                // Check if any fill intersects the keepout
                SHAPE_POLY_SET intersection = *fill;
                intersection.BooleanIntersection( keepoutOutline );
 
                if( intersection.OutlineCount() > 0 )
                {
                    double intersectionArea = 0;
 
                    for( int i = 0; i < intersection.OutlineCount(); i++ )
                        intersectionArea += std::abs( intersection.Outline( i ).Area() );
 
                    // Allow for small numerical errors (less than 1 square mm)
                    if( intersectionArea > 1e6 )
                    {
                        BOOST_TEST_MESSAGE( wxString::Format( "Zone %s fill on layer %s overlaps keepout by %.2f sq mm",
                                                              zone->GetNetname(),
                                                              m_board->GetLayerName( layer ),
                                                              intersectionArea / 1e6 ) );
                        violationCount++;
                    }
                }
            }
        }
    }
 
    BOOST_CHECK_MESSAGE( violationCount == 0,
                         wxString::Format( "Found %d zone fills overlapping keepout areas. This indicates "
                                           "issue 22809 - iterative refiller ignores zone keepouts.",
                                           violationCount ) );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionTHPadInnerLayerFlashing, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue22826/issue22826", m_board );
 
    KI_TEST::FillZones( m_board.get() );
 
    PCB_LAYER_ID in2Cu = m_board->GetLayerID( wxT( "In2.Cu" ) );
    int padsWithMissingFlashing = 0;
    int totalConditionalPads = 0;
 
    for( FOOTPRINT* footprint : m_board->Footprints() )
    {
        for( PAD* pad : footprint->Pads() )
        {
            if( !pad->GetRemoveUnconnected() )
                continue;
 
            if( !pad->HasHole() )
                continue;
 
            if( pad->GetNetname() != "VBUS_DUT" && pad->GetNetname() != "VBUS_DBG" )
                continue;
 
            totalConditionalPads++;
 
            // Check if the pad should flash on In2.Cu
            bool shouldFlash = false;
 
            for( ZONE* zone : m_board->Zones() )
            {
                if( zone->GetIsRuleArea() )
                    continue;
 
                if( zone->GetNetCode() != pad->GetNetCode() )
                    continue;
 
                if( !zone->IsOnLayer( in2Cu ) )
                    continue;
 
                if( zone->Outline()->Contains( pad->GetPosition() ) )
                {
                    shouldFlash = true;
                    break;
                }
            }
 
            if( shouldFlash && !pad->FlashLayer( in2Cu ) )
            {
                BOOST_TEST_MESSAGE( wxString::Format( "Pad %s at (%d, %d) on net %s is inside zone but not flashing "
                                                      "on In2.Cu",
                                                      pad->GetNumber(),
                                                      pad->GetPosition().x,
                                                      pad->GetPosition().y,
                                                      pad->GetNetname() ) );
                padsWithMissingFlashing++;
            }
        }
    }
 
    BOOST_TEST_MESSAGE( wxString::Format( "Total conditional pads: %d, Pads with missing flashing: %d",
                                          totalConditionalPads,
                                          padsWithMissingFlashing ) );
 
    BOOST_CHECK_MESSAGE( padsWithMissingFlashing == 0,
                         wxString::Format( "Found %d TH pads that should flash on inner layers but don't. This "
                                           "indicates issue 22826 is not fixed.",
                                           padsWithMissingFlashing ) );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionThermalReliefAnnularRing45, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue24865/issue24865", m_board );
 
    KI_TEST::FillZones( m_board.get() );
 
    const PCB_LAYER_ID innerLayers[] = { m_board->GetLayerID( wxT( "In1.Cu" ) ),
                                         m_board->GetLayerID( wxT( "In2.Cu" ) ) };
 
    int padsWithMissingFlashing = 0;
    int totalConditionalPads = 0;
 
    for( FOOTPRINT* footprint : m_board->Footprints() )
    {
        for( PAD* pad : footprint->Pads() )
        {
            if( !pad->GetRemoveUnconnected() || !pad->HasHole() )
                continue;
 
            for( PCB_LAYER_ID layer : innerLayers )
            {
                bool shouldFlash = false;
 
                for( ZONE* zone : m_board->Zones() )
                {
                    if( zone->GetIsRuleArea() || zone->GetNetCode() != pad->GetNetCode() )
                        continue;
 
                    if( !zone->IsOnLayer( layer ) )
                        continue;
 
                    if( zone->Outline()->Contains( pad->GetPosition() ) )
                    {
                        shouldFlash = true;
                        break;
                    }
                }
 
                if( !shouldFlash )
                    continue;
 
                totalConditionalPads++;
 
                if( !pad->FlashLayer( layer ) )
                {
                    BOOST_TEST_MESSAGE( wxString::Format( "Pad %s (drill %.2f mm, spoke angle %.0f deg) on net %s "
                                                          "is inside the zone but not flashing on %s",
                                                          pad->GetNumber(),
                                                          pcbIUScale.IUTomm( pad->GetDrillSize().x ),
                                                          pad->GetThermalSpokeAngle().AsDegrees(),
                                                          pad->GetNetname(),
                                                          m_board->GetLayerName( layer ) ) );
                    padsWithMissingFlashing++;
                }
            }
        }
    }
 
    BOOST_TEST_MESSAGE( wxString::Format( "Pads inside inner-layer zones: %d, missing flashing: %d",
                                          totalConditionalPads,
                                          padsWithMissingFlashing ) );
 
    BOOST_CHECK_MESSAGE( padsWithMissingFlashing == 0,
                         wxString::Format( "Found %d TH pads inside a same-net inner-layer zone that lost their "
                                           "annular ring after fill. This indicates issue 24865 is not fixed.",
                                           padsWithMissingFlashing ) );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionRoundRectTeardropGeometry, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue19405_roundrect_teardrop", m_board );
 
    // Set up tool manager for teardrop generation
    TOOL_MANAGER toolMgr;
    toolMgr.SetEnvironment( m_board.get(), nullptr, nullptr, nullptr, nullptr );
 
    KI_TEST::DUMMY_TOOL* dummyTool = new KI_TEST::DUMMY_TOOL();
    toolMgr.RegisterTool( dummyTool );
 
    // Generate teardrops
    BOARD_COMMIT commit( dummyTool );
    TEARDROP_MANAGER teardropMgr( m_board.get(), &toolMgr );
    teardropMgr.UpdateTeardrops( commit, nullptr, nullptr, true );
 
    if( !commit.Empty() )
        commit.Push( _( "Add teardrops" ), SKIP_UNDO | SKIP_SET_DIRTY );
 
    // Find teardrop zones
    int teardropCount = 0;
    bool foundBadTeardrop = false;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( !zone->IsTeardropArea() )
            continue;
 
        teardropCount++;
 
        // Get the teardrop outline
        const SHAPE_POLY_SET* outline = zone->Outline();
 
        if( !outline || outline->OutlineCount() == 0 )
            continue;
 
        const SHAPE_LINE_CHAIN& chain = outline->Outline( 0 );
 
        // Check that the teardrop polygon is convex or at least doesn't have
        // any sharp concave angles that would indicate intersection with the pad corner.
        // A well-formed teardrop should have all turns in the same direction
        // (or very close to it) except at the pad anchor points.
        int concaveCount = 0;
 
        for( int i = 0; i < chain.PointCount(); i++ )
        {
            int prev = ( i == 0 ) ? chain.PointCount() - 1 : i - 1;
            int next = ( i + 1 ) % chain.PointCount();
 
            VECTOR2I v1 = chain.CPoint( i ) - chain.CPoint( prev );
            VECTOR2I v2 = chain.CPoint( next ) - chain.CPoint( i );
 
            // Cross product gives handedness of turn
            int64_t cross = (int64_t) v1.x * v2.y - (int64_t) v1.y * v2.x;
 
            // Count significant concave turns (negative cross product for CCW polygons)
            // Small values are numerical noise
            if( cross < -1000 )
                concaveCount++;
        }
 
        // A teardrop should have at most 2-3 concave points (at the pad anchor points)
        // Many concave points indicate the curve is intersecting the pad corner
        if( concaveCount > 5 )
        {
            BOOST_TEST_MESSAGE( wxString::Format( "Teardrop has %d concave vertices, indicating possible corner "
                                                  "intersection",
                                                   concaveCount ) );
            foundBadTeardrop = true;
        }
    }
 
    BOOST_CHECK_MESSAGE( teardropCount > 0, "Expected at least one teardrop zone" );
 
    BOOST_CHECK_MESSAGE( !foundBadTeardrop, "Found teardrop with excessive concave vertices, indicating "
                                            "issue 19405 - teardrop curve intersecting rounded rectangle corner" );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionTeardropSpike, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "teardrop_spike", m_board );
 
    TOOL_MANAGER toolMgr;
    toolMgr.SetEnvironment( m_board.get(), nullptr, nullptr, nullptr, nullptr );
 
    KI_TEST::DUMMY_TOOL* dummyTool = new KI_TEST::DUMMY_TOOL();
    toolMgr.RegisterTool( dummyTool );
 
    BOARD_COMMIT commit( dummyTool );
    TEARDROP_MANAGER teardropMgr( m_board.get(), &toolMgr );
    teardropMgr.UpdateTeardrops( commit, nullptr, nullptr, true );
 
    if( !commit.Empty() )
        commit.Push( _( "Add teardrops" ), SKIP_UNDO | SKIP_SET_DIRTY );
 
    int  teardropCount = 0;
    bool foundSpike = false;
 
    const int maxError = m_board->GetDesignSettings().m_MaxError;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( !zone->IsTeardropArea() )
            continue;
 
        teardropCount++;
 
        PCB_LAYER_ID layer = zone->GetFirstLayer();
        int          netcode = zone->GetNetCode();
 
        // A well-formed teardrop only ever covers the copper it bridges: the pads/vias it
        // anchors on and the track(s) it follows. Build that corridor from all copper on the
        // teardrop's net and layer (generously inflated) and require the teardrop to lie
        // inside it. A spike sweeps area outside the corridor.
        SHAPE_POLY_SET corridor;
 
        for( FOOTPRINT* fp : m_board->Footprints() )
        {
            for( PAD* pad : fp->Pads() )
            {
                if( pad->GetNetCode() == netcode && pad->IsOnLayer( layer ) )
                    pad->TransformShapeToPolygon( corridor, layer, 0, maxError, ERROR_OUTSIDE );
            }
        }
 
        for( PCB_TRACK* track : m_board->Tracks() )
        {
            if( track->GetNetCode() == netcode && track->IsOnLayer( layer ) )
                track->TransformShapeToPolygon( corridor, layer, 0, maxError, ERROR_OUTSIDE );
        }
 
        // Inflate by a full track width so the teardrop's flare toward the pad, which is
        // legitimately wider than the bare track, is comfortably inside the corridor.
        corridor.Inflate( pcbIUScale.mmToIU( 0.127 ), CORNER_STRATEGY::ROUND_ALL_CORNERS,
                          maxError );
        corridor.Simplify();
 
        SHAPE_POLY_SET outside = *zone->Outline();
        outside.BooleanSubtract( corridor );
 
        double tdArea = std::abs( zone->Outline()->Area() );
        double outArea = std::abs( outside.Area() );
        double ratio = tdArea > 0 ? outArea / tdArea : 0.0;
 
        BOOST_TEST_MESSAGE( wxString::Format( "Teardrop on layer %d: area %.0f, area outside corridor %.0f (%.1f%%)",
                                              (int) layer,
                                              tdArea,
                                              outArea,
                                              ratio * 100.0 ) );
 
        if( ratio > 0.02 )
        {
            foundSpike = true;
            BOOST_TEST_MESSAGE( wxString::Format( "Teardrop on layer %d sweeps %.1f%% of its area outside the "
                                                  "track/pad corridor (spike)",
                                                  (int) layer,
                                                  ratio * 100.0 ) );
        }
    }
 
    BOOST_CHECK_MESSAGE( teardropCount > 0, "Expected at least one teardrop zone" );
    BOOST_CHECK_MESSAGE( !foundSpike, "A teardrop vertex spikes outside the track/pad corridor it should follow" );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionTeardropCustomPadAnchor, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "teardrop_custom_pad_anchor", m_board );
 
    TOOL_MANAGER toolMgr;
    toolMgr.SetEnvironment( m_board.get(), nullptr, nullptr, nullptr, nullptr );
 
    KI_TEST::DUMMY_TOOL* dummyTool = new KI_TEST::DUMMY_TOOL();
    toolMgr.RegisterTool( dummyTool );
 
    BOARD_COMMIT     commit( dummyTool );
    TEARDROP_MANAGER teardropMgr( m_board.get(), &toolMgr );
    teardropMgr.UpdateTeardrops( commit, nullptr, nullptr, true );
 
    if( !commit.Empty() )
        commit.Push( _( "Add teardrops" ), SKIP_UNDO | SKIP_SET_DIRTY );
 
    // A teardrop reaches at most its max length along the track plus the pad's minor width into
    // the pad, so their sum bounds every legitimate vertex and still sits far below the 7mm spike
    int maxReach = 0;
 
    for( FOOTPRINT* fp : m_board->Footprints() )
    {
        for( PAD* pad : fp->Pads() )
        {
            const TEARDROP_PARAMETERS& prms = pad->GetTeardropParams();
            VECTOR2I                   size = pad->GetSize( PADSTACK::ALL_LAYERS );
 
            maxReach = std::max( maxReach, prms.m_TdMaxLen + std::min( size.x, size.y ) );
        }
    }
 
    BOOST_REQUIRE( maxReach > 0 );
 
    int  teardropCount = 0;
    bool foundSpike = false;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( !zone->IsTeardropArea() )
            continue;
 
        teardropCount++;
 
        PCB_LAYER_ID layer = zone->GetFirstLayer();
 
        for( const VECTOR2I& pt : zone->Outline()->Outline( 0 ).CPoints() )
        {
            SEG::ecoord bestSq = std::numeric_limits<SEG::ecoord>::max();
 
            for( PCB_TRACK* track : m_board->Tracks() )
            {
                if( !track->IsOnLayer( layer ) )
                    continue;
 
                bestSq = std::min( bestSq, SEG( track->GetStart(), track->GetEnd() ).SquaredDistance( pt ) );
            }
 
            double dist = std::sqrt( (double) bestSq );
 
            if( dist > maxReach )
            {
                foundSpike = true;
                BOOST_TEST_MESSAGE( wxString::Format( "Teardrop vertex (%.4f, %.4f) is %.4f mm from the nearest "
                                                      "track, max allowed %.4f mm",
                                                      pcbIUScale.IUTomm( pt.x ), pcbIUScale.IUTomm( pt.y ),
                                                      pcbIUScale.IUTomm( KiROUND( dist ) ),
                                                      pcbIUScale.IUTomm( maxReach ) ) );
            }
        }
    }
 
    // Both pads numbered "2" cover the track end, so without this a dropped custom-pad teardrop
    // would leave the circular pad's teardrop passing the spike check alone
    BOOST_CHECK_MESSAGE( teardropCount == 2, wxString::Format( "Expected a teardrop on each of the two pads covering "
                                                               "the track end, found %d",
                                                               teardropCount ) );
    BOOST_CHECK_MESSAGE( !foundSpike, "A teardrop reaches far past its anchor track, indicating it was built around "
                                      "the custom pad's anchor position instead of the copper the track enters" );
}
 
 
BOOST_FIXTURE_TEST_CASE( RegressionTeardropArcAnchor, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "teardrop_arc_anchor", m_board );
 
    TOOL_MANAGER toolMgr;
    toolMgr.SetEnvironment( m_board.get(), nullptr, nullptr, nullptr, nullptr );
 
    KI_TEST::DUMMY_TOOL* dummyTool = new KI_TEST::DUMMY_TOOL();
    toolMgr.RegisterTool( dummyTool );
 
    BOARD_COMMIT     commit( dummyTool );
    TEARDROP_MANAGER teardropMgr( m_board.get(), &toolMgr );
    teardropMgr.UpdateTeardrops( commit, nullptr, nullptr, true );
 
    if( !commit.Empty() )
        commit.Push( _( "Add teardrops" ), SKIP_UNDO | SKIP_SET_DIRTY );
 
    BOOST_REQUIRE( !m_board->Footprints().empty() );
    BOOST_REQUIRE( !m_board->Footprints().front()->Pads().empty() );
 
    PAD* pad = m_board->Footprints().front()->Pads().front();
 
    const int minEdgeLen = 2 * m_board->GetDesignSettings().m_MaxError;
 
    int teardropCount = 0;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( !zone->IsTeardropArea() )
            continue;
 
        teardropCount++;
 
        const SHAPE_LINE_CHAIN& chain = zone->Outline()->COutline( 0 );
 
        SEG         throat;
        SEG::ecoord bestSq = -1;
 
        for( int ii = 0; ii < chain.SegmentCount(); ii++ )
        {
            SEG seg = chain.CSegment( ii );
 
            if( seg.Length() < minEdgeLen )
                continue;
 
            SEG::ecoord distSq = ( seg.Center() - pad->GetPosition() ).SquaredEuclideanNorm();
 
            if( distSq > bestSq )
            {
                bestSq = distSq;
                throat = seg;
            }
        }
 
        BOOST_REQUIRE( bestSq >= 0 );
 
        for( const VECTOR2I& pt : { throat.A, throat.B } )
        {
            bool onTrack = false;
 
            for( PCB_TRACK* track : m_board->Tracks() )
                onTrack |= track->HitTest( pt, 0 );
 
            BOOST_CHECK_MESSAGE( onTrack, wxString::Format( "Teardrop anchor (%.6f, %.6f) mm is off the "
                                                            "track copper",
                                                            pcbIUScale.IUTomm( pt.x ), pcbIUScale.IUTomm( pt.y ) ) );
        }
    }
 
    BOOST_CHECK_MESSAGE( teardropCount == 1, wxString::Format( "Expected 1 teardrop zone, found %d", teardropCount ) );
}
 

BOOST_FIXTURE_TEST_CASE( OvalPadTeardropGeometry, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "oval_teardrop", m_board );
 
    // Set up tool manager for teardrop generation
    TOOL_MANAGER toolMgr;
    toolMgr.SetEnvironment( m_board.get(), nullptr, nullptr, nullptr, nullptr );
 
    KI_TEST::DUMMY_TOOL* dummyTool = new KI_TEST::DUMMY_TOOL();
    toolMgr.RegisterTool( dummyTool );
 
    // Generate teardrops
    BOARD_COMMIT commit( dummyTool );
    TEARDROP_MANAGER teardropMgr( m_board.get(), &toolMgr );
    teardropMgr.UpdateTeardrops( commit, nullptr, nullptr, true );
 
    if( !commit.Empty() )
        commit.Push( _( "Add teardrops" ), SKIP_UNDO | SKIP_SET_DIRTY );
 
    // Find teardrop zones
    int teardropCount = 0;
    bool foundBadTeardrop = false;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( !zone->IsTeardropArea() )
            continue;
 
        teardropCount++;
 
        const SHAPE_POLY_SET* outline = zone->Outline();
 
        if( !outline || outline->OutlineCount() == 0 )
            continue;
 
        const SHAPE_LINE_CHAIN& chain = outline->Outline( 0 );
 
        // Check for excessive concave vertices that would indicate the teardrop curve
        // is not tangent to the oval's semicircular end
        int concaveCount = 0;
 
        for( int i = 0; i < chain.PointCount(); i++ )
        {
            int prev = ( i == 0 ) ? chain.PointCount() - 1 : i - 1;
            int next = ( i + 1 ) % chain.PointCount();
 
            VECTOR2I v1 = chain.CPoint( i ) - chain.CPoint( prev );
            VECTOR2I v2 = chain.CPoint( next ) - chain.CPoint( i );
 
            int64_t cross = (int64_t) v1.x * v2.y - (int64_t) v1.y * v2.x;
 
            if( cross < -1000 )
                concaveCount++;
        }
 
        if( concaveCount > 5 )
        {
            BOOST_TEST_MESSAGE( wxString::Format( "Oval teardrop has %d concave vertices", concaveCount ) );
            foundBadTeardrop = true;
        }
    }
 
    BOOST_CHECK_MESSAGE( teardropCount > 0, "Expected at least one teardrop zone" );
 
    BOOST_CHECK_MESSAGE( !foundBadTeardrop, "Found teardrop with excessive concave vertices on oval pad, "
                                            "indicating curve is not tangent to semicircular end" );
}
 

BOOST_FIXTURE_TEST_CASE( LargeCircleTeardropGeometry, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "large_circle_teardrop", m_board );
 
    // Set up tool manager for teardrop generation
    TOOL_MANAGER toolMgr;
    toolMgr.SetEnvironment( m_board.get(), nullptr, nullptr, nullptr, nullptr );
 
    KI_TEST::DUMMY_TOOL* dummyTool = new KI_TEST::DUMMY_TOOL();
    toolMgr.RegisterTool( dummyTool );
 
    // Generate teardrops
    BOARD_COMMIT commit( dummyTool );
    TEARDROP_MANAGER teardropMgr( m_board.get(), &toolMgr );
    teardropMgr.UpdateTeardrops( commit, nullptr, nullptr, true );
 
    if( !commit.Empty() )
        commit.Push( _( "Add teardrops" ), SKIP_UNDO | SKIP_SET_DIRTY );
 
    // Find the pad and its teardrop
    PAD* largePad = nullptr;
 
    for( FOOTPRINT* fp : m_board->Footprints() )
    {
        for( PAD* pad : fp->Pads() )
        {
            if( pad->GetShape( F_Cu ) == PAD_SHAPE::CIRCLE )
            {
                largePad = pad;
                break;
            }
        }
    }
 
    BOOST_REQUIRE_MESSAGE( largePad != nullptr, "Expected a circular pad in test board" );
 
    int padRadius = largePad->GetSize( F_Cu ).x / 2;
    VECTOR2I padCenter = largePad->GetPosition();
 
    // Find teardrop zones
    int teardropCount = 0;
    bool foundBadTeardrop = false;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( !zone->IsTeardropArea() )
            continue;
 
        teardropCount++;
 
        const SHAPE_POLY_SET* outline = zone->Outline();
 
        if( !outline || outline->OutlineCount() == 0 )
            continue;
 
        const SHAPE_LINE_CHAIN& chain = outline->Outline( 0 );
 
        // Check for excessive concave vertices
        int concaveCount = 0;
 
        for( int i = 0; i < chain.PointCount(); i++ )
        {
            int prev = ( i == 0 ) ? chain.PointCount() - 1 : i - 1;
            int next = ( i + 1 ) % chain.PointCount();
 
            VECTOR2I v1 = chain.CPoint( i ) - chain.CPoint( prev );
            VECTOR2I v2 = chain.CPoint( next ) - chain.CPoint( i );
 
            int64_t cross = (int64_t) v1.x * v2.y - (int64_t) v1.y * v2.x;
 
            if( cross < -1000 )
                concaveCount++;
        }
 
        if( concaveCount > 5 )
        {
            BOOST_TEST_MESSAGE( wxString::Format( "Large circle teardrop has %d concave vertices", concaveCount ) );
            foundBadTeardrop = true;
        }
 
        // Also verify that the teardrop anchor points near the pad are approximately
        // on the circle edge (within tolerance)
        int maxError = m_board->GetDesignSettings().m_MaxError;
 
        for( int i = 0; i < chain.PointCount(); i++ )
        {
            VECTOR2I pt = chain.CPoint( i );
            double dist = ( pt - padCenter ).EuclideanNorm();
 
            // Points that are close to the circle should be approximately on it
            if( dist > padRadius * 0.5 && dist < padRadius * 1.5 )
            {
                double deviation = std::abs( dist - padRadius );
 
                // Allow some tolerance for polygon approximation
                if( deviation > maxError * 5 && deviation < padRadius * 0.2 )
                {
                    BOOST_TEST_MESSAGE( wxString::Format(
                            "Teardrop point at distance %.2f from pad center (radius %.2f), "
                            "deviation %.2f exceeds tolerance",
                            dist / 1000.0, padRadius / 1000.0, deviation / 1000.0 ) );
                }
            }
        }
    }
 
    BOOST_CHECK_MESSAGE( teardropCount > 0, "Expected at least one teardrop zone" );
 
    BOOST_CHECK_MESSAGE( !foundBadTeardrop,
                         "Found teardrop with excessive concave vertices on large circle, "
                         "indicating anchor points may not be on circle edge" );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionCoincidentPadClearance, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue23123_minimal", m_board );
 
    KI_TEST::FillZones( m_board.get() );
 
    // After filling, every pad whose net differs from the zone must have clearance.
    // Check each zone/pad combination on each shared layer.
    int violations = 0;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( zone->GetIsRuleArea() )
            continue;
 
        for( PCB_LAYER_ID layer : zone->GetLayerSet().Seq() )
        {
            if( !zone->HasFilledPolysForLayer( layer ) )
                continue;
 
            const std::shared_ptr<SHAPE_POLY_SET>& fill = zone->GetFilledPolysList( layer );
 
            for( PAD* pad : m_board->GetPads() )
            {
                if( !pad->IsOnLayer( layer ) )
                    continue;
 
                if( pad->GetNetCode() == zone->GetNetCode() )
                    continue;
 
                std::shared_ptr<SHAPE> padShape = pad->GetEffectiveShape( layer );
                int clearance = padShape->GetClearance( fill.get() );
 
                if( clearance < 1 )
                {
                    BOOST_TEST_MESSAGE( wxString::Format(
                            "Pad %s (net %s) at (%d, %d) has zero clearance to zone %s "
                            "on layer %s",
                            pad->GetNumber(), pad->GetNetname(),
                            pad->GetPosition().x, pad->GetPosition().y,
                            zone->GetNetname(), m_board->GetLayerName( layer ) ) );
                    violations++;
                }
            }
        }
    }
 
    BOOST_CHECK_MESSAGE( violations == 0,
                         wxString::Format( "Found %d pads with missing zone clearance. "
                                           "Coincident pads with different nets must not be "
                                           "deduplicated in zone fill knockout.",
                                           violations ) );
}
 

BOOST_FIXTURE_TEST_CASE( ZoneViaNetClearance, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "connect/connect", m_board );
 
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
 
    KI_TEST::FillZones( m_board.get() );
 
    std::vector<DRC_ITEM> violations;
 
    bds.m_DRCEngine->InitEngine( wxFileName() );
 
    bds.m_DRCEngine->SetViolationHandler(
            [&]( const std::shared_ptr<DRC_ITEM>& aItem, const VECTOR2I& aPos, int aLayer,
                 const std::function<void( PCB_MARKER* )>& aPathGenerator )
            {
                if( aItem->GetErrorCode() == DRCE_CLEARANCE )
                {
                    BOARD_ITEM* item_a = m_board->ResolveItem( aItem->GetMainItemID() );
                    BOARD_ITEM* item_b = m_board->ResolveItem( aItem->GetAuxItemID() );
 
                    ZONE* zone_a = dynamic_cast<ZONE*>( item_a );
                    ZONE* zone_b = dynamic_cast<ZONE*>( item_b );
 
                    if( zone_a || zone_b )
                        violations.push_back( *aItem );
                }
            } );
 
    bds.m_DRCEngine->RunTests( EDA_UNITS::MM, true, false );
 
    BOOST_CHECK_EQUAL( violations.size(), 0 );
}
 

BOOST_FIXTURE_TEST_CASE( ZoneLayerSpecificRules, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue23339_zone_layer_rules", m_board );
 
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
 
    // First verify that EvalRules returns the correct clearance per layer
    ZONE* hvZone = nullptr;
    ZONE* lvZone = nullptr;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( zone->GetNetname() == "HV_NET" )
            hvZone = zone;
        else if( zone->GetNetname() == "LV_NET" )
            lvZone = zone;
    }
 
    BOOST_REQUIRE( hvZone );
    BOOST_REQUIRE( lvZone );
 
    // Outer layer rule should give 4.6mm clearance on F.Cu
    DRC_CONSTRAINT outerConstraint = bds.m_DRCEngine->EvalRules( CLEARANCE_CONSTRAINT, hvZone, lvZone, F_Cu );
 
    BOOST_TEST_MESSAGE( "F.Cu clearance: " << outerConstraint.GetValue().Min()
                        << " (expected " << pcbIUScale.mmToIU( 4.6 ) << ")" );
    BOOST_CHECK_EQUAL( outerConstraint.GetValue().Min(), pcbIUScale.mmToIU( 4.6 ) );
 
    // Inner layer rule should give 2.3mm clearance on In1.Cu
    DRC_CONSTRAINT innerConstraint = bds.m_DRCEngine->EvalRules( CLEARANCE_CONSTRAINT, hvZone, lvZone, In1_Cu );
 
    BOOST_TEST_MESSAGE( "In1.Cu clearance: " << innerConstraint.GetValue().Min()
                        << " (expected " << pcbIUScale.mmToIU( 2.3 ) << ")" );
    BOOST_CHECK_EQUAL( innerConstraint.GetValue().Min(), pcbIUScale.mmToIU( 2.3 ) );
 
    // Now fill zones and check that fills actually respect the clearances
    KI_TEST::FillZones( m_board.get() );
 
    // Run DRC and verify no clearance violations between zones
    std::vector<DRC_ITEM> violations;
 
    bds.m_DRCEngine->InitEngine( wxFileName() );
 
    bds.m_DRCEngine->SetViolationHandler(
            [&]( const std::shared_ptr<DRC_ITEM>& aItem, const VECTOR2I& aPos, int aLayer,
                 const std::function<void( PCB_MARKER* )>& aPathGenerator )
            {
                if( aItem->GetErrorCode() == DRCE_CLEARANCE )
                {
                    BOARD_ITEM* item_a = m_board->ResolveItem( aItem->GetMainItemID() );
                    BOARD_ITEM* item_b = m_board->ResolveItem( aItem->GetAuxItemID() );
 
                    ZONE* zone_a = dynamic_cast<ZONE*>( item_a );
                    ZONE* zone_b = dynamic_cast<ZONE*>( item_b );
 
                    if( zone_a && zone_b )
                    {
                        BOOST_TEST_MESSAGE( "Zone-to-zone clearance violation on layer "
                                            << aLayer << ": " << aItem->GetErrorMessage( true ) );
                        violations.push_back( *aItem );
                    }
                }
            } );
 
    bds.m_DRCEngine->RunTests( EDA_UNITS::MM, true, false );
 
    BOOST_CHECK_EQUAL( violations.size(), 0 );
}
 
 
BOOST_FIXTURE_TEST_CASE( RegressionZoneFillMinWidthAfterKnockout, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue23332_min_width/issue23332_min_width", m_board );
 
    KI_TEST::FillZones( m_board.get() );
 
    int epsilon = pcbIUScale.mmToIU( 0.001 );
 
    for( ZONE* zone : m_board->Zones() )
    {
        int half_min_width = zone->GetMinThickness() / 2;
 
        if( half_min_width - epsilon <= epsilon )
            continue;
 
        for( PCB_LAYER_ID layer : zone->GetLayerSet().Seq() )
        {
            if( !zone->HasFilledPolysForLayer( layer ) )
                continue;
 
            std::shared_ptr<SHAPE_POLY_SET> fill = zone->GetFilledPolysList( layer );
 
            if( !fill || fill->OutlineCount() == 0 )
                continue;
 
            // Check each filled island individually so that a tiny thin sliver
            // isn't masked by a large zone's total area
            for( int ii = 0; ii < fill->OutlineCount(); ii++ )
            {
                SHAPE_POLY_SET island;
                island.AddOutline( fill->Outline( ii ) );
 
                for( int jj = 0; jj < fill->HoleCount( ii ); jj++ )
                    island.AddHole( fill->Hole( ii, jj ) );
 
                double originalArea = island.Area();
 
                if( originalArea <= 0 )
                    continue;
 
                SHAPE_POLY_SET test = island.CloneDropTriangulation();
 
                test.Deflate( half_min_width - epsilon, CORNER_STRATEGY::CHAMFER_ALL_CORNERS, ARC_HIGH_DEF );
 
                test.Inflate( half_min_width - epsilon, CORNER_STRATEGY::ROUND_ALL_CORNERS, ARC_HIGH_DEF, true );
 
                double prunedArea = test.Area();
                double areaLoss = ( originalArea - prunedArea ) / originalArea;
 
                BOOST_TEST_MESSAGE( wxString::Format( "Zone %s layer %d island %d: area=%.0f, loss=%.4f%%",
                                                      zone->GetNetname(),
                                                      static_cast<int>( layer ),
                                                      ii,
                                                      originalArea,
                                                      areaLoss * 100.0 ) );
 
                BOOST_CHECK_MESSAGE( areaLoss < 0.01,
                                     wxString::Format( "Zone %s layer %d island %d lost %.2f%% area from "
                                                       "min-width pruning (min_width=%.3fmm)",
                                                       zone->GetNetname(),
                                                       static_cast<int>( layer ),
                                                       ii,
                                                       areaLoss * 100.0,
                                                       zone->GetMinThickness() / (double) pcbIUScale.IU_PER_MM ) );
            }
        }
    }
}
 
 
BOOST_FIXTURE_TEST_CASE( RegressionSameNetOverlappingZones, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue23418/testing", m_board );
 
    KI_TEST::FillZones( m_board.get() );
 
    int epsilon = pcbIUScale.mmToIU( 0.001 );
 
    for( ZONE* zone : m_board->Zones() )
    {
        int half_min_width = zone->GetMinThickness() / 2;
 
        if( half_min_width - epsilon <= epsilon )
            continue;
 
        for( PCB_LAYER_ID layer : zone->GetLayerSet().Seq() )
        {
            if( !zone->HasFilledPolysForLayer( layer ) )
                continue;
 
            std::shared_ptr<SHAPE_POLY_SET> fill = zone->GetFilledPolysList( layer );
 
            if( !fill || fill->OutlineCount() == 0 )
                continue;
 
            for( int ii = 0; ii < fill->OutlineCount(); ii++ )
            {
                SHAPE_POLY_SET island;
                island.AddOutline( fill->Outline( ii ) );
 
                for( int jj = 0; jj < fill->HoleCount( ii ); jj++ )
                    island.AddHole( fill->Hole( ii, jj ) );
 
                double originalArea = island.Area();
 
                if( originalArea <= 0 )
                    continue;
 
                SHAPE_POLY_SET test = island.CloneDropTriangulation();
 
                test.Deflate( half_min_width - epsilon, CORNER_STRATEGY::CHAMFER_ALL_CORNERS, ARC_HIGH_DEF );
 
                test.Inflate( half_min_width - epsilon, CORNER_STRATEGY::ROUND_ALL_CORNERS, ARC_HIGH_DEF, true );
 
                double prunedArea = test.Area();
                double areaLoss = ( originalArea - prunedArea ) / originalArea;
 
                BOOST_CHECK_MESSAGE( areaLoss < 0.01,
                                     wxString::Format( "Zone %s (priority %d) layer %d island %d lost %.2f%% area "
                                                       "from min-width pruning, suggesting degenerate geometry "
                                                       "from overlapping same-net zones",
                                                       zone->GetNetname(),
                                                       zone->GetAssignedPriority(),
                                                       static_cast<int>( layer ),
                                                       ii,
                                                       areaLoss * 100.0 ) );
            }
        }
    }
}
 
 
BOOST_FIXTURE_TEST_CASE( RegressionDiffNetOverlappingZones, ZONE_FILL_TEST_FIXTURE )
{
    ADVANCED_CFG& cfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
    bool          originalIterativeRefill = cfg.m_ZoneFillIterativeRefill;
 
    struct ScopeGuard
    {
        bool& ref;
        bool  orig;
        ~ScopeGuard() { ref = orig; }
    } guard{ cfg.m_ZoneFillIterativeRefill, originalIterativeRefill };
 
    auto runAreaLossCheck =
            [this]( bool aIterative )
            {
                ADVANCED_CFG& innerCfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
                innerCfg.m_ZoneFillIterativeRefill = aIterative;
 
                KI_TEST::LoadBoard( m_settingsManager, "issue23418_diffnet/testing", m_board );
                KI_TEST::FillZones( m_board.get() );
 
                int epsilon = pcbIUScale.mmToIU( 0.001 );
 
                for( ZONE* zone : m_board->Zones() )
                {
                    int half_min_width = zone->GetMinThickness() / 2;
 
                    if( half_min_width - epsilon <= epsilon )
                        continue;
 
                    for( PCB_LAYER_ID layer : zone->GetLayerSet().Seq() )
                    {
                        if( !zone->HasFilledPolysForLayer( layer ) )
                            continue;
 
                        std::shared_ptr<SHAPE_POLY_SET> fill = zone->GetFilledPolysList( layer );
 
                        if( !fill || fill->OutlineCount() == 0 )
                            continue;
 
                        for( int ii = 0; ii < fill->OutlineCount(); ii++ )
                        {
                            SHAPE_POLY_SET island;
                            island.AddOutline( fill->Outline( ii ) );
 
                            for( int jj = 0; jj < fill->HoleCount( ii ); jj++ )
                                island.AddHole( fill->Hole( ii, jj ) );
 
                            double originalArea = island.Area();
 
                            if( originalArea <= 0 )
                                continue;
 
                            SHAPE_POLY_SET test = island.CloneDropTriangulation();
 
                            test.Deflate( half_min_width - epsilon, CORNER_STRATEGY::CHAMFER_ALL_CORNERS,
                                          ARC_HIGH_DEF );
 
                            test.Inflate( half_min_width - epsilon, CORNER_STRATEGY::ROUND_ALL_CORNERS,
                                          ARC_HIGH_DEF, true );
 
                            double prunedArea = test.Area();
                            double areaLoss = ( originalArea - prunedArea ) / originalArea;
 
                            BOOST_CHECK_MESSAGE( areaLoss < 0.01,
                                                 wxString::Format( "Zone %s (priority %d) layer %d island %d lost "
                                                                   "%.2f%% area (iterative=%d), suggesting degenerate "
                                                                   "geometry from different-net zone knockouts",
                                                                   zone->GetNetname(),
                                                                   zone->GetAssignedPriority(),
                                                                   static_cast<int>( layer ),
                                                                   ii,
                                                                   areaLoss * 100.0,
                                                                   aIterative ) );
                        }
                    }
                }
            };
 
    runAreaLossCheck( false );
    runAreaLossCheck( true );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionThermalReliefsToNowhere, ZONE_FILL_TEST_FIXTURE )
{
    ADVANCED_CFG& cfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
    bool          originalIterativeRefill = cfg.m_ZoneFillIterativeRefill;
    cfg.m_ZoneFillIterativeRefill = true;
 
    struct ScopeGuard
    {
        bool& ref;
        bool  orig;
        ~ScopeGuard() { ref = orig; }
    } guard{ cfg.m_ZoneFillIterativeRefill, originalIterativeRefill };
 
    KI_TEST::LoadBoard( m_settingsManager, "issue23535_minimal/issue23535_minimal", m_board );
 
    KI_TEST::FillZones( m_board.get() );
 
    ZONE* gndZone = nullptr;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( zone->GetNetname() == "GND" )
            gndZone = zone;
    }
 
    BOOST_REQUIRE( gndZone );
    BOOST_REQUIRE( gndZone->HasFilledPolysForLayer( F_Cu ) );
 
    const std::shared_ptr<SHAPE_POLY_SET>& gndFill = gndZone->GetFilledPolysList( F_Cu );
 
    // The pad is at (6.5mm, 5mm) with size 1.5mm and thermal gap 0.5mm.
    // The right edge of the pad is at x=7.25mm, thermal gap extends to x=7.75mm.
    // After zone knockout, GND fill stops at roughly x=7.5mm.
    //
    // A thermal-relief-to-nowhere spoke would create copper at a point inside the
    // thermal gap but past the zone fill boundary.  Check a point at (7.4mm, 5mm)
    // which is in the thermal gap (x > 7.25) and near the knockout edge.
    VECTOR2I spokeTestPoint( pcbIUScale.mmToIU( 7.4 ), pcbIUScale.mmToIU( 5.0 ) );
 
    bool hasSpokeToNowhere = gndFill->Contains( spokeTestPoint );
 
    BOOST_CHECK_MESSAGE( !hasSpokeToNowhere, "GND zone fill contains copper at the thermal gap test point (7.4, 5.0), "
                                             "indicating a thermal relief spoke to nowhere (issue 23535)." );
 
    // Also verify that the left-pointing spoke still connects properly.
    // A point at (5.6mm, 5mm) is in the thermal gap on the left side and should have
    // copper from a valid left-pointing spoke.
    VECTOR2I validSpokePoint( pcbIUScale.mmToIU( 5.6 ), pcbIUScale.mmToIU( 5.0 ) );
 
    bool hasValidSpoke = gndFill->Contains( validSpokePoint );
 
    BOOST_CHECK_MESSAGE( hasValidSpoke, "GND zone fill does not contain copper at the valid spoke test point "
                                        "(5.6, 5.0). The fix may have incorrectly removed valid spokes." );
}
 

BOOST_FIXTURE_TEST_CASE( OffCenterTeardropSymmetry, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "off_center_teardrop", m_board );
 
    TOOL_MANAGER toolMgr;
    toolMgr.SetEnvironment( m_board.get(), nullptr, nullptr, nullptr, nullptr );
 
    KI_TEST::DUMMY_TOOL* dummyTool = new KI_TEST::DUMMY_TOOL();
    toolMgr.RegisterTool( dummyTool );
 
    BOARD_COMMIT commit( dummyTool );
    TEARDROP_MANAGER teardropMgr( m_board.get(), &toolMgr );
    teardropMgr.UpdateTeardrops( commit, nullptr, nullptr, true );
 
    if( !commit.Empty() )
        commit.Push( _( "Add teardrops" ), SKIP_UNDO | SKIP_SET_DIRTY );
 
    // The test board has a 3mm circle pad at (100, 100) with a 0.25mm track connecting
    // at (100.75, 99) heading to (115, 99). The track enters the pad off-center: 1mm above
    // and 0.75mm right of center. The teardrop should be approximately symmetric about the
    // track's axis (the line from ~(100.75, 99) toward (115, 99), i.e., horizontal).
 
    int teardropCount = 0;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( !zone->IsTeardropArea() )
            continue;
 
        teardropCount++;
 
        const SHAPE_POLY_SET* outline = zone->Outline();
 
        if( !outline || outline->OutlineCount() == 0 )
            continue;
 
        const SHAPE_LINE_CHAIN& chain = outline->Outline( 0 );
 
        // The track axis is approximately at Y=99mm (in board coordinates = 99 * 1e6 nm).
        // Measure the maximum extent above and below this axis across all teardrop vertices.
        int trackY = pcbIUScale.mmToIU( 99 );
        int maxAbove = 0;
        int maxBelow = 0;
 
        for( int i = 0; i < chain.PointCount(); i++ )
        {
            int dy = chain.CPoint( i ).y - trackY;
 
            if( dy < 0 )
                maxAbove = std::max( maxAbove, -dy );
            else
                maxBelow = std::max( maxBelow, dy );
        }
 
        // Both sides should have some extent (the teardrop flares out on both sides)
        BOOST_CHECK_MESSAGE( maxAbove > 0 && maxBelow > 0,
                             "Teardrop should extend on both sides of the track axis" );
 
        if( maxAbove > 0 && maxBelow > 0 )
        {
            // The two sides should be approximately equal. Allow 30% asymmetry tolerance
            // to account for polygon approximation of the circular pad and convex hull rounding.
            double ratio = static_cast<double>( std::min( maxAbove, maxBelow ) )
                         / static_cast<double>( std::max( maxAbove, maxBelow ) );
 
            BOOST_CHECK_MESSAGE( ratio > 0.7,
                                 wxString::Format( "Teardrop asymmetry ratio %.2f is too low (above=%d, below=%d). "
                                                   "Expected roughly symmetric about the track axis.",
                                                   ratio,
                                                   maxAbove,
                                                   maxBelow ) );
        }
    }
 
    BOOST_CHECK_MESSAGE( teardropCount > 0, "Expected at least one teardrop zone for off-center track" );
}
 
 
// 0.1 mm beside the track axis and inside the 0.15 mm half width, so the track crosses the item.
static const VECTOR2I crossedPosition( pcbIUScale.mmToIU( 0.1 ), pcbIUScale.mmToIU( 10 ) );
 
 
static PCB_TRACK* addCrossingTrack( BOARD& aBoard )
{
    PCB_TRACK* track = new PCB_TRACK( &aBoard );
    track->SetLayer( F_Cu );
    track->SetWidth( pcbIUScale.mmToIU( 0.3 ) );
    track->SetStart( VECTOR2I( 0, 0 ) );
    track->SetEnd( VECTOR2I( 0, pcbIUScale.mmToIU( 20 ) ) );
    aBoard.Add( track );
    track->SetNetCode( 1 );
 
    return track;
}
 
 
static void checkCrossingTrackTeardropsStayOnCopper( BOARD& aBoard, const PCB_TRACK* aTrack,
                                                     const BOARD_ITEM* aCrossed )
{
    aBoard.BuildConnectivity();
 
    TOOL_MANAGER toolMgr;
    toolMgr.SetEnvironment( &aBoard, nullptr, nullptr, nullptr, nullptr );
 
    KI_TEST::DUMMY_TOOL* dummyTool = new KI_TEST::DUMMY_TOOL();
    toolMgr.RegisterTool( dummyTool );
 
    BOARD_COMMIT     commit( dummyTool );
    TEARDROP_MANAGER teardropMgr( &aBoard, &toolMgr );
    teardropMgr.UpdateTeardrops( commit, nullptr, nullptr, true );
 
    if( !commit.Empty() )
        commit.Push( _( "Add teardrops" ), SKIP_UNDO | SKIP_SET_DIRTY );
 
    // A straight edged teardrop has five corners. Two sit on the track, two on the crossed item
    // and one behind its centre. The pad hit test uses an inscribed polygon, so allow its error.
    int tolerance = std::max( aBoard.GetDesignSettings().m_MaxError, pcbIUScale.mmToIU( 0.001 ) );
    int teardrops = 0;
 
    for( ZONE* zone : aBoard.Zones() )
    {
        if( !zone->IsTeardropArea() )
            continue;
 
        teardrops++;
 
        for( const VECTOR2I& pt : zone->Outline()->COutline( 0 ).CPoints() )
        {
            BOOST_CHECK_MESSAGE( aTrack->HitTest( pt, tolerance ) || aCrossed->HitTest( pt, tolerance ),
                                 wxString::Format( "Teardrop corner (%.3f, %.3f) mm lies outside both "
                                                   "the track and the crossed item",
                                                   pcbIUScale.IUTomm( pt.x ), pcbIUScale.IUTomm( pt.y ) ) );
        }
    }
 
    BOOST_CHECK_EQUAL( teardrops, 2 );
}
 
 
BOOST_AUTO_TEST_CASE( CrossingTrackTeardropOnViaStaysOnTrack )
{
    BOARD board;
    board.Add( new NETINFO_ITEM( &board, wxT( "N1" ), 1 ) );
 
    PCB_TRACK* track = addCrossingTrack( board );
 
    PCB_VIA* via = new PCB_VIA( &board );
    via->SetPadstackMode( PADSTACK::MODE::NORMAL );
    via->SetPosition( crossedPosition );
    via->SetLayerPair( F_Cu, B_Cu );
    via->SetDrill( pcbIUScale.mmToIU( 0.3 ) );
    via->SetWidth( PADSTACK::ALL_LAYERS, pcbIUScale.mmToIU( 1.0 ) );
    via->GetTeardropParams().m_Enabled = true;
    via->GetTeardropParams().m_CurvedEdges = false;
    board.Add( via );
    via->SetNetCode( 1 );
 
    checkCrossingTrackTeardropsStayOnCopper( board, track, via );
}
 
 
BOOST_AUTO_TEST_CASE( CrossingTrackTeardropOnPadStaysOnTrack )
{
    BOARD board;
    board.Add( new NETINFO_ITEM( &board, wxT( "N1" ), 1 ) );
 
    PCB_TRACK* track = addCrossingTrack( board );
 
    FOOTPRINT* footprint = new FOOTPRINT( &board );
    PAD*       pad = new PAD( footprint );
    pad->SetPadstackMode( PADSTACK::MODE::NORMAL );
    pad->SetAttribute( PAD_ATTRIB::PTH );
    pad->SetShape( PADSTACK::ALL_LAYERS, PAD_SHAPE::CIRCLE );
    pad->SetLayerSet( LSET::AllCuMask() );
    pad->SetSize( PADSTACK::ALL_LAYERS, VECTOR2I( pcbIUScale.mmToIU( 1.0 ), pcbIUScale.mmToIU( 1.0 ) ) );
    pad->SetDrillSize( VECTOR2I( pcbIUScale.mmToIU( 0.3 ), pcbIUScale.mmToIU( 0.3 ) ) );
    pad->SetPosition( crossedPosition );
    pad->GetTeardropParams().m_Enabled = true;
    pad->GetTeardropParams().m_CurvedEdges = false;
    footprint->Add( pad );
    board.Add( footprint );
    pad->SetNetCode( 1 );
 
    checkCrossingTrackTeardropsStayOnCopper( board, track, pad );
}
 

BOOST_FIXTURE_TEST_CASE( ElongatedPadTeardropContainment, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "teardrop_elongated_pad", m_board );
 
    TOOL_MANAGER toolMgr;
    toolMgr.SetEnvironment( m_board.get(), nullptr, nullptr, nullptr, nullptr );
 
    KI_TEST::DUMMY_TOOL* dummyTool = new KI_TEST::DUMMY_TOOL();
    toolMgr.RegisterTool( dummyTool );
 
    BOARD_COMMIT commit( dummyTool );
    TEARDROP_MANAGER teardropMgr( m_board.get(), &toolMgr );
    teardropMgr.UpdateTeardrops( commit, nullptr, nullptr, true );
 
    if( !commit.Empty() )
        commit.Push( _( "Add teardrops" ), SKIP_UNDO | SKIP_SET_DIRTY );
 
    // Find the pad to build an expanded outline for containment checking.
    // The pad is at board position (136.45, 100.819) with size (3.5, 0.3) rotated 270 deg,
    // giving board extents X: [136.3, 136.6], Y: [99.069, 102.569].
    PAD* testPad = nullptr;
 
    for( FOOTPRINT* fp : m_board->Footprints() )
    {
        for( PAD* pad : fp->Pads() )
        {
            if( pad->GetNumber() == "7" )
            {
                testPad = pad;
                break;
            }
        }
    }
 
    BOOST_REQUIRE_MESSAGE( testPad != nullptr, "Could not find pad 7 in test board" );
 
    // Build the pad outline polygon with a small tolerance for the track half-width
    int            tolerance = std::max( m_board->GetDesignSettings().m_MaxError, pcbIUScale.mmToIU( 0.001 ) );
    SHAPE_POLY_SET padPoly;
    testPad->TransformShapeToPolygon( padPoly, B_Cu, tolerance, m_board->GetDesignSettings().m_MaxError,
                                      ERROR_OUTSIDE );
 
    int teardropCount = 0;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( !zone->IsTeardropArea() )
            continue;
 
        const SHAPE_POLY_SET* outline = zone->Outline();
 
        BOOST_REQUIRE_MESSAGE( outline && outline->OutlineCount() > 0, "Teardrop zone has no outline" );
 
        teardropCount++;
 
        const SHAPE_LINE_CHAIN& chain = outline->Outline( 0 );
 
        // Check each vertex of the teardrop. Vertices on the pad side (closer to pad center
        // than to the track anchor) must be inside the expanded pad outline.
        VECTOR2I padCenter = testPad->GetPosition();
 
        // The track anchor region is near (136.45, 99.16) in mm, i.e., outside the pad.
        // We only check vertices that are closer to the pad center than to the track anchor.
        VECTOR2I trackAnchor( pcbIUScale.mmToIU( 136.45 ), pcbIUScale.mmToIU( 99.16 ) );
 
        for( int i = 0; i < chain.PointCount(); i++ )
        {
            VECTOR2I pt = chain.CPoint( i );
            double distToPad = ( VECTOR2D( pt ) - VECTOR2D( padCenter ) ).EuclideanNorm();
            double distToTrack = ( VECTOR2D( pt ) - VECTOR2D( trackAnchor ) ).EuclideanNorm();
 
            // Only check vertices on the pad side of the teardrop
            if( distToPad < distToTrack )
            {
                BOOST_CHECK_MESSAGE( padPoly.Contains( pt ),
                                     wxString::Format( "Teardrop vertex (%d, %d) is outside the pad outline with "
                                                       "%d nm tolerance",
                                                       pt.x, pt.y,
                                                       tolerance ) );
            }
        }
    }
 
    BOOST_CHECK_MESSAGE( teardropCount > 0, "Expected at least one teardrop zone for elongated pad" );
}
 

BOOST_FIXTURE_TEST_CASE( TwoSegmentAngledTeardropNoSelfIntersection, ZONE_FILL_TEST_FIXTURE )
{
    auto runVariant =
            [&]( bool aCurvedEdges )
            {
                KI_TEST::LoadBoard( m_settingsManager, "two_segment_teardrop", m_board );
 
                for( PCB_TRACK* track : m_board->Tracks() )
                {
                    if( track->Type() == PCB_VIA_T )
                    {
                        static_cast<PCB_VIA*>( track )->SetTeardropCurved( aCurvedEdges );
                        break;
                    }
                }
 
                TOOL_MANAGER toolMgr;
                toolMgr.SetEnvironment( m_board.get(), nullptr, nullptr, nullptr, nullptr );
 
                KI_TEST::DUMMY_TOOL* dummyTool = new KI_TEST::DUMMY_TOOL();
                toolMgr.RegisterTool( dummyTool );
 
                BOARD_COMMIT commit( dummyTool );
                TEARDROP_MANAGER teardropMgr( m_board.get(), &toolMgr );
                teardropMgr.UpdateTeardrops( commit, nullptr, nullptr, true );
 
                if( !commit.Empty() )
                    commit.Push( _( "Add teardrops" ), SKIP_UNDO | SKIP_SET_DIRTY );
 
                int  teardropCount = 0;
                bool foundSelfIntersection = false;
 
                for( ZONE* zone : m_board->Zones() )
                {
                    if( !zone->IsTeardropArea() )
                        continue;
 
                    teardropCount++;
 
                    const SHAPE_POLY_SET* outline = zone->Outline();
 
                    if( !outline || outline->OutlineCount() == 0 )
                        continue;
 
                    const SHAPE_LINE_CHAIN& chain = outline->Outline( 0 );
                    int n = chain.PointCount();
 
                    for( int i = 0; i < n && !foundSelfIntersection; i++ )
                    {
                        SEG segA( chain.CPoint( i ), chain.CPoint( ( i + 1 ) % n ) );
 
                        for( int j = i + 2; j < n; j++ )
                        {
                            if( i == 0 && j == n - 1 )
                                continue;
 
                            SEG segB( chain.CPoint( j ), chain.CPoint( ( j + 1 ) % n ) );
                            OPT_VECTOR2I hit = segA.Intersect( segB );
 
                            if( hit.has_value() )
                            {
                                BOOST_TEST_MESSAGE( wxString::Format( "Self-intersection at (%d, %d) between edges "
                                                                      "%d and %d (curved=%s)",
                                                                      hit->x, hit->y,
                                                                      i,
                                                                      j,
                                                                      aCurvedEdges ? "yes" : "no" ) );
 
                                for( int k = 0; k < n; k++ )
                                {
                                    BOOST_TEST_MESSAGE( wxString::Format( "  pt[%d] = (%d, %d)", k,
                                                                          chain.CPoint( k ).x, chain.CPoint( k ).y ) );
                                }
 
                                foundSelfIntersection = true;
                                break;
                            }
                        }
                    }
                }
 
                BOOST_CHECK_MESSAGE( teardropCount > 0,
                                     wxString::Format( "Expected at least one teardrop zone (curved=%s)",
                                                       aCurvedEdges ? "yes" : "no" ) );
 
                BOOST_CHECK_MESSAGE( !foundSelfIntersection,
                                     wxString::Format( "Teardrop polygon has self-intersecting edges (curved=%s)",
                                                       aCurvedEdges ? "yes" : "no" ) );
            };
 
    runVariant( true );
    runVariant( false );
}
 

BOOST_FIXTURE_TEST_CASE( OffCenterTwoSegmentTeardropNoSpike, ZONE_FILL_TEST_FIXTURE )
{
    auto runVariant = [&]( bool aCurvedEdges )
    {
        KI_TEST::LoadBoard( m_settingsManager, "teardrop_offcenter_two_segment", m_board );
 
        VECTOR2I viaPos;
        int      viaRadius = 0;
 
        for( PCB_TRACK* track : m_board->Tracks() )
        {
            if( track->Type() == PCB_VIA_T )
            {
                PCB_VIA* via = static_cast<PCB_VIA*>( track );
                via->SetPadstackMode( PADSTACK::MODE::NORMAL );
                via->SetTeardropCurved( aCurvedEdges );
                viaPos = via->GetPosition();
                viaRadius = via->GetWidth( PADSTACK::ALL_LAYERS ) / 2;
                break;
            }
        }
 
        BOOST_REQUIRE( viaRadius > 0 );
 
        TOOL_MANAGER toolMgr;
        toolMgr.SetEnvironment( m_board.get(), nullptr, nullptr, nullptr, nullptr );
 
        KI_TEST::DUMMY_TOOL* dummyTool = new KI_TEST::DUMMY_TOOL();
        toolMgr.RegisterTool( dummyTool );
 
        BOARD_COMMIT commit( dummyTool );
        TEARDROP_MANAGER teardropMgr( m_board.get(), &toolMgr );
        teardropMgr.UpdateTeardrops( commit, nullptr, nullptr, true );
 
        if( !commit.Empty() )
            commit.Push( _( "Add teardrops" ), SKIP_UNDO | SKIP_SET_DIRTY );
 
        // The crafted board's first segment emerges from the via by ~10 um on a 100 um
        // track width; the emerging-length filter rejects it and no teardrop is built.
        const double maxBackSideDist = viaRadius * 1.2;
        int      teardropCount = 0;
        int      spikingPoints = 0;
        VECTOR2I worstPoint;
        double   worstDistance = 0.0;
 
        for( ZONE* zone : m_board->Zones() )
        {
            if( !zone->IsTeardropArea() )
                continue;
 
            teardropCount++;
 
            const SHAPE_POLY_SET* outline = zone->Outline();
 
            if( !outline || outline->OutlineCount() == 0 )
                continue;
 
            const SHAPE_LINE_CHAIN& chain = outline->Outline( 0 );
 
            for( int i = 0; i < chain.PointCount(); i++ )
            {
                const VECTOR2I& pt = chain.CPoint( i );
                VECTOR2I        rel = pt - viaPos;
 
                // Only consider points on the back side (opposite the track entry).
                if( rel.x >= 0 )
                    continue;
 
                double dist = rel.EuclideanNorm();
 
                if( dist > maxBackSideDist )
                {
                    spikingPoints++;
 
                    if( dist > worstDistance )
                    {
                        worstDistance = dist;
                        worstPoint = pt;
                    }
                }
            }
        }
 
        BOOST_CHECK_MESSAGE( teardropCount == 0,
                             wxString::Format( "Expected no teardrop on grazing-entry track (emergence below "
                                               "track width), got %d (curved=%s)",
                                               teardropCount,
                                               aCurvedEdges ? "yes" : "no" ) );
 
        BOOST_CHECK_MESSAGE( spikingPoints == 0,
                             wxString::Format( "Found %d teardrop polygon vertex/vertices outside the expected "
                                               "envelope (worst at (%d, %d), %f mm from via center; curved=%s)",
                                               spikingPoints,
                                               worstPoint.x, worstPoint.y,
                                               worstDistance / pcbIUScale.IU_PER_MM,
                                               aCurvedEdges ? "yes" : "no" ) );
    };
 
    runVariant( true );
    runVariant( false );
}
 

BOOST_FIXTURE_TEST_CASE( MultiTrackSharedInsideJunctionNoSelfIntersection, ZONE_FILL_TEST_FIXTURE )
{
    auto runVariant = [&]( bool aCurvedEdges )
    {
        KI_TEST::LoadBoard( m_settingsManager, "teardrop_multi_inside_via", m_board );
 
        for( PCB_TRACK* track : m_board->Tracks() )
        {
            if( track->Type() == PCB_VIA_T )
            {
                static_cast<PCB_VIA*>( track )->SetTeardropCurved( aCurvedEdges );
                break;
            }
        }
 
        TOOL_MANAGER toolMgr;
        toolMgr.SetEnvironment( m_board.get(), nullptr, nullptr, nullptr, nullptr );
 
        KI_TEST::DUMMY_TOOL* dummyTool = new KI_TEST::DUMMY_TOOL();
        toolMgr.RegisterTool( dummyTool );
 
        BOARD_COMMIT commit( dummyTool );
        TEARDROP_MANAGER teardropMgr( m_board.get(), &toolMgr );
        teardropMgr.UpdateTeardrops( commit, nullptr, nullptr, true );
 
        if( !commit.Empty() )
            commit.Push( _( "Add teardrops" ), SKIP_UNDO | SKIP_SET_DIRTY );
 
        int      teardropCount = 0;
        int      selfIntersectingCount = 0;
        VECTOR2I worstPoint;
 
        for( ZONE* zone : m_board->Zones() )
        {
            if( !zone->IsTeardropArea() )
                continue;
 
            teardropCount++;
 
            const SHAPE_POLY_SET* outline = zone->Outline();
 
            if( !outline || outline->OutlineCount() == 0 )
                continue;
 
            const SHAPE_LINE_CHAIN& chain = outline->Outline( 0 );
            int                     n = chain.PointCount();
            bool                    intersected = false;
 
            for( int i = 0; i < n && !intersected; i++ )
            {
                SEG segA( chain.CPoint( i ), chain.CPoint( ( i + 1 ) % n ) );
 
                for( int j = i + 2; j < n; j++ )
                {
                    if( i == 0 && j == n - 1 )
                        continue;
 
                    SEG          segB( chain.CPoint( j ), chain.CPoint( ( j + 1 ) % n ) );
                    OPT_VECTOR2I hit = segA.Intersect( segB );
 
                    if( hit.has_value() )
                    {
                        BOOST_TEST_MESSAGE( wxString::Format( "Teardrop polygon self-intersection at (%d, %d) "
                                                              "between edges %d and %d (curved=%s)",
                                                              hit->x, hit->y,
                                                              i,
                                                              j,
                                                              aCurvedEdges ? "yes" : "no" ) );
 
                        worstPoint = hit.value();
                        intersected = true;
                        break;
                    }
                }
            }
 
            if( intersected )
                selfIntersectingCount++;
        }
 
        BOOST_CHECK_MESSAGE( teardropCount > 0,
                             wxString::Format( "Expected at least one teardrop zone (curved=%s)",
                                               aCurvedEdges ? "yes" : "no" ) );
 
        BOOST_CHECK_MESSAGE( selfIntersectingCount == 0,
                             wxString::Format( "%d of %d teardrop polygon(s) self-intersect (worst at (%d, %d); "
                                               "curved=%s)",
                                               selfIntersectingCount,
                                               teardropCount,
                                               worstPoint.x, worstPoint.y,
                                               aCurvedEdges ? "yes" : "no" ) );
    };
 
    runVariant( true );
    runVariant( false );
}
 

BOOST_FIXTURE_TEST_CASE( CloseViaShortRadialTrackTeardrop, ZONE_FILL_TEST_FIXTURE )
{
    auto runVariant = [&]( const wxString& aFixture, bool aCurvedEdges )
    {
        KI_TEST::LoadBoard( m_settingsManager, aFixture, m_board );
 
        for( PCB_TRACK* track : m_board->Tracks() )
        {
            if( track->Type() == PCB_VIA_T )
                static_cast<PCB_VIA*>( track )->SetTeardropCurved( aCurvedEdges );
        }
 
        for( FOOTPRINT* footprint : m_board->Footprints() )
        {
            for( PAD* pad : footprint->Pads() )
                pad->SetTeardropCurved( aCurvedEdges );
        }
 
        TOOL_MANAGER toolMgr;
        toolMgr.SetEnvironment( m_board.get(), nullptr, nullptr, nullptr, nullptr );
 
        KI_TEST::DUMMY_TOOL* dummyTool = new KI_TEST::DUMMY_TOOL();
        toolMgr.RegisterTool( dummyTool );
 
        BOARD_COMMIT     commit( dummyTool );
        TEARDROP_MANAGER teardropMgr( m_board.get(), &toolMgr );
        teardropMgr.UpdateTeardrops( commit, nullptr, nullptr, true );
 
        if( !commit.Empty() )
            commit.Push( _( "Add teardrops" ), SKIP_UNDO | SKIP_SET_DIRTY );
 
        int      teardropCount = 0;
        VECTOR2I padPos = ( *m_board->Footprints().begin() )->Pads()[0]->GetPosition();
        bool     padHasTeardrop = false;
 
        for( ZONE* zone : m_board->Zones() )
        {
            if( !zone->IsTeardropArea() )
                continue;
 
            teardropCount++;
 
            if( zone->Outline()->Contains( padPos ) )
                padHasTeardrop = true;
        }
 
        BOOST_CHECK_MESSAGE( padHasTeardrop,
                             wxString::Format( "Expected the pad-anchored teardrop on the short track joining the "
                                               "pad and the close via in %s, got %d teardrop(s) (curved=%s)",
                                               aFixture,
                                               teardropCount,
                                               aCurvedEdges ? "yes" : "no" ) );
    };
 
    runVariant( "teardrop_close_via", true );
    runVariant( "teardrop_close_via", false );
    runVariant( "teardrop_close_via_rotated_pad", true );
    runVariant( "teardrop_close_via_rotated_pad", false );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionKeepoutBoundaryMissingFill, ZONE_FILL_TEST_FIXTURE )
{
    ADVANCED_CFG& cfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
    bool          originalIterativeRefill = cfg.m_ZoneFillIterativeRefill;
 
    struct ScopeGuard
    {
        bool& ref;
        bool  orig;
        ~ScopeGuard() { ref = orig; }
    } guard{ cfg.m_ZoneFillIterativeRefill, originalIterativeRefill };
 
    auto getTotalFilledArea =
            [this]() -> double
            {
                double totalArea = 0;
 
                for( ZONE* zone : m_board->Zones() )
                {
                    if( zone->GetIsRuleArea() )
                        continue;
 
                    for( PCB_LAYER_ID layer : zone->GetLayerSet().Seq() )
                    {
                        if( !zone->HasFilledPolysForLayer( layer ) )
                            continue;
 
                        std::shared_ptr<SHAPE_POLY_SET> fill = zone->GetFilledPolysList( layer );
 
                        if( fill )
                            totalArea += std::abs( fill->Area() );
                    }
                }
 
                return totalArea;
            };
 
    auto refillAndMeasure =
            [this, &cfg, &getTotalFilledArea]( bool aIterative ) -> double
            {
                cfg.m_ZoneFillIterativeRefill = aIterative;
 
                KI_TEST::LoadBoard( m_settingsManager, "issue23515/issue23515", m_board );
 
                double storedArea = getTotalFilledArea();
 
                BOOST_REQUIRE_MESSAGE( storedArea > 0, "Stored v9 fill has zero area" );
 
                KI_TEST::FillZones( m_board.get() );
                return getTotalFilledArea();
            };
 
    KI_TEST::LoadBoard( m_settingsManager, "issue23515/issue23515", m_board );
 
    double storedArea = getTotalFilledArea();
 
    BOOST_REQUIRE_MESSAGE( storedArea > 0, "Stored v9 fill has zero area" );
 
    double nonIterativeArea = refillAndMeasure( false );
    double iterativeArea = refillAndMeasure( true );
    double nonIterativeAreaRatio = nonIterativeArea / storedArea;
    double iterativeAreaRatio = iterativeArea / storedArea;
 
    BOOST_CHECK_MESSAGE( nonIterativeAreaRatio > 0.99999,
                         wxString::Format( "Non-iterative refill lost %.4f%% versus stored v9 fill "
                                           "(stored=%.2f mm^2, non-iterative=%.2f mm^2). This suggests "
                                           "missing pieces near keepout boundaries (issue 23515).",
                                           ( 1.0 - nonIterativeAreaRatio ) * 100.0,
                                           storedArea / 1e6,
                                           nonIterativeArea / 1e6 ) );
 
    BOOST_CHECK_MESSAGE( iterativeAreaRatio > 0.99999,
                         wxString::Format( "Iterative refill lost %.4f%% versus stored v9 fill "
                                           "(stored=%.2f mm^2, iterative=%.2f mm^2). "
                                           "This suggests missing pieces near keepout boundaries (issue 23515).",
                                           ( 1.0 - iterativeAreaRatio ) * 100.0,
                                           storedArea / 1e6,
                                           iterativeArea / 1e6 ) );
}
 

BOOST_FIXTURE_TEST_CASE( HatchZoneViaConnectionRespectsSetting, ZONE_FILL_TEST_FIXTURE )
{
    m_board = std::make_unique<BOARD>();
 
    // Two-layer board is sufficient for this test
    m_board->SetCopperLayerCount( 2 );
 
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
    bds.SetCopperLayerCount( 2 );
 
    bds.m_MinClearance = pcbIUScale.mmToIU( 0.2 );
 
    // Add a GND net
    NETINFO_ITEM* gndNet = new NETINFO_ITEM( m_board.get(), wxT( "GND" ) );
    m_board->Add( gndNet );
    int gndNetCode = gndNet->GetNetCode();
 
    // Via dimensions: 2.0mm diameter, 1.0mm drill - large enough to span multiple hatch cells
    // so the via always touches webbing lines regardless of position within the hatch grid.
    int viaDiam  = pcbIUScale.mmToIU( 2.0 );
    int viaDrill = pcbIUScale.mmToIU( 1.0 );
 
    // Hatch zone parameters: 0.5mm gap, 0.3mm thickness.  The via (radius=1.0mm) is wider
    // than the gap, so it will always intersect webbing in FULL mode.  The thermal gap
    // (0.5mm) makes the knockout circle radius = 1.0+0.5 = 1.5mm.
    int hatchGap       = pcbIUScale.mmToIU( 0.5 );
    int hatchThickness = pcbIUScale.mmToIU( 0.3 );
 
    // Via center at 10mm,10mm (middle of the zone)
    VECTOR2I viaPos( pcbIUScale.mmToIU( 10 ), pcbIUScale.mmToIU( 10 ) );
 
    auto makeVia =
            [&]() -> PCB_VIA*
            {
                PCB_VIA* via = new PCB_VIA( m_board.get() );
                via->SetPadstackMode( PADSTACK::MODE::NORMAL );
                via->SetPosition( viaPos );
                via->SetLayerPair( F_Cu, B_Cu );
                via->SetDrill( viaDrill );
                via->SetWidth( PADSTACK::ALL_LAYERS, viaDiam );
                via->SetNetCode( gndNetCode );
                m_board->Add( via );
                return via;
            };
 
    auto makeHatchZone =
            [&]( ZONE_CONNECTION aConnection ) -> ZONE*
            {
                ZONE* zone = new ZONE( m_board.get() );
                zone->SetLayer( F_Cu );
                zone->SetNetCode( gndNetCode );
                zone->SetFillMode( ZONE_FILL_MODE::HATCH_PATTERN );
                zone->SetHatchGap( hatchGap );
                zone->SetHatchThickness( hatchThickness );
                zone->SetPadConnection( aConnection );
                zone->SetMinThickness( pcbIUScale.mmToIU( 0.2 ) );
                zone->SetThermalReliefGap( pcbIUScale.mmToIU( 0.5 ) );
                zone->SetThermalReliefSpokeWidth( pcbIUScale.mmToIU( 0.5 ) );
 
                SHAPE_POLY_SET outline;
                outline.NewOutline();
                outline.Append( VECTOR2I( pcbIUScale.mmToIU( 1 ), pcbIUScale.mmToIU( 1 ) ) );
                outline.Append( VECTOR2I( pcbIUScale.mmToIU( 19 ), pcbIUScale.mmToIU( 1 ) ) );
                outline.Append( VECTOR2I( pcbIUScale.mmToIU( 19 ), pcbIUScale.mmToIU( 19 ) ) );
                outline.Append( VECTOR2I( pcbIUScale.mmToIU( 1 ), pcbIUScale.mmToIU( 19 ) ) );
                zone->AddPolygon( outline.COutline( 0 ) );
 
                m_board->Add( zone );
                return zone;
            };
 
    auto initDRC =
            [&]()
            {
                m_board->BuildConnectivity();
                auto drcEngine = std::make_shared<DRC_ENGINE>( m_board.get(), &bds );
                drcEngine->InitEngine( wxFileName() );
                bds.m_DRCEngine = drcEngine;
            };
 
    // The thermal relief adds a circular ring around the via that covers hatch holes which
    // would otherwise be open.  With viaRadius=1.0mm, thermalGap=0.5mm, spokeWidth=0.5mm:
    //   ring outer radius = 1.75mm, inner radius = 1.25mm
    //   ring area added inside hatch holes > knockout area removed from webbing
    //   net result: THERMAL fill area > FULL fill area by ~0.4 sq mm
    // FULL connection skips both the knockout and the ring addition, so the THERMAL fill
    // should be measurably larger than the FULL fill.
 
    double fullFillArea    = 0.0;
    double thermalFillArea = 0.0;
 
    // Test 1: FULL connection
    {
        PCB_VIA* via  = makeVia();
        ZONE*    zone = makeHatchZone( ZONE_CONNECTION::FULL );
 
        initDRC();
        KI_TEST::FillZones( m_board.get() );
 
        BOOST_REQUIRE_MESSAGE( zone->HasFilledPolysForLayer( F_Cu ),
                               "Zone should have fill on F.Cu with FULL connection" );
 
        const std::shared_ptr<SHAPE_POLY_SET>& fill = zone->GetFilledPolysList( F_Cu );
 
        for( int i = 0; i < fill->OutlineCount(); i++ )
            fullFillArea += std::abs( fill->Outline( i ).Area() );
 
        m_board->Remove( via );
        m_board->Remove( zone );
        delete via;
        delete zone;
    }
 
    // Test 2: THERMAL connection
    {
        PCB_VIA* via  = makeVia();
        ZONE*    zone = makeHatchZone( ZONE_CONNECTION::THERMAL );
 
        initDRC();
        KI_TEST::FillZones( m_board.get() );
 
        BOOST_REQUIRE_MESSAGE( zone->HasFilledPolysForLayer( F_Cu ),
                               "Zone should have fill on F.Cu with THERMAL connection" );
 
        const std::shared_ptr<SHAPE_POLY_SET>& fill = zone->GetFilledPolysList( F_Cu );
 
        for( int i = 0; i < fill->OutlineCount(); i++ )
            thermalFillArea += std::abs( fill->Outline( i ).Area() );
 
        m_board->Remove( via );
        m_board->Remove( zone );
        delete via;
        delete zone;
    }
 
    // The THERMAL fill should have more area than the FULL fill because a thermal ring was
    // added around the via, filling hatch holes that would otherwise be open.
    // Use a 0.2 sq mm threshold to avoid sensitivity to small edge effects.
    double iuPerMM       = pcbIUScale.IU_PER_MM;
    double areaThreshold = 0.2 * iuPerMM * iuPerMM;  // 0.2 sq mm in IU^2
 
    double areaIU2toMM2 = 1.0 / ( iuPerMM * iuPerMM );
 
    BOOST_CHECK_MESSAGE( thermalFillArea > fullFillArea + areaThreshold,
                         wxString::Format( "THERMAL connection fill area (%.2f sq mm) should be larger than "
                                           "FULL fill area (%.2f sq mm) by at least 0.2 sq mm. If they are "
                                           "equal or FULL is larger, thermal ring was not added for THERMAL "
                                           "connection, or thermal ring was incorrectly added for FULL connection "
                                           "(issue 23516 regression).",
                                           thermalFillArea * areaIU2toMM2,
                                           fullFillArea * areaIU2toMM2 ) );
}
 

BOOST_FIXTURE_TEST_CASE( HatchZoneFullViaStaysConnected, ZONE_FILL_TEST_FIXTURE )
{
    m_board = std::make_unique<BOARD>();
    m_board->SetCopperLayerCount( 2 );
 
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
    bds.SetCopperLayerCount( 2 );
    bds.m_MinClearance = pcbIUScale.mmToIU( 0.2 );
 
    NETINFO_ITEM* gndNet = new NETINFO_ITEM( m_board.get(), wxT( "GND" ) );
    m_board->Add( gndNet );
    int gndNetCode = gndNet->GetNetCode();
 
    // Via diameter (0.4mm) is much smaller than the hatch gap (2.0mm), so a via centred in a
    // hole sits entirely inside that hole with no copper around it unless the hole is dropped.
    int viaDiam = pcbIUScale.mmToIU( 0.4 );
    int viaDrill = pcbIUScale.mmToIU( 0.2 );
 
    int hatchGap = pcbIUScale.mmToIU( 2.0 );
    int hatchThickness = pcbIUScale.mmToIU( 0.3 );
 
    auto makeHatchZone = [&]() -> ZONE*
    {
        ZONE* zone = new ZONE( m_board.get() );
        zone->SetLayer( F_Cu );
        zone->SetNetCode( gndNetCode );
        zone->SetFillMode( ZONE_FILL_MODE::HATCH_PATTERN );
        zone->SetHatchGap( hatchGap );
        zone->SetHatchThickness( hatchThickness );
        zone->SetPadConnection( ZONE_CONNECTION::FULL );
        zone->SetMinThickness( pcbIUScale.mmToIU( 0.2 ) );
 
        SHAPE_POLY_SET outline;
        outline.NewOutline();
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 0 ), pcbIUScale.mmToIU( 0 ) ) );
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 20 ), pcbIUScale.mmToIU( 0 ) ) );
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 20 ), pcbIUScale.mmToIU( 20 ) ) );
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 0 ), pcbIUScale.mmToIU( 20 ) ) );
        zone->AddPolygon( outline.COutline( 0 ) );
 
        m_board->Add( zone );
        return zone;
    };
 
    // Sweep over one full grid period (gridsize = hatchThickness + hatchGap = 2.3mm) so the
    // via is guaranteed to land inside a hole at several positions regardless of grid phase.
    const int    steps = 8;
    const double startMM = 9.0;
    const double stepMM = 2.3 / steps;
 
    int isolatedCount = 0;
    int testedCount = 0;
 
    for( int ix = 0; ix < steps; ix++ )
    {
        for( int iy = 0; iy < steps; iy++ )
        {
            VECTOR2I viaPos( pcbIUScale.mmToIU( startMM + ix * stepMM ), pcbIUScale.mmToIU( startMM + iy * stepMM ) );
 
            PCB_VIA* via = new PCB_VIA( m_board.get() );
            via->SetPadstackMode( PADSTACK::MODE::NORMAL );
            via->SetPosition( viaPos );
            via->SetLayerPair( F_Cu, B_Cu );
            via->SetDrill( viaDrill );
            via->SetWidth( PADSTACK::ALL_LAYERS, viaDiam );
            via->SetNetCode( gndNetCode );
            m_board->Add( via );
 
            ZONE* zone = makeHatchZone();
 
            m_board->BuildConnectivity();
            auto drcEngine = std::make_shared<DRC_ENGINE>( m_board.get(), &bds );
            drcEngine->InitEngine( wxFileName() );
            bds.m_DRCEngine = drcEngine;
 
            KI_TEST::FillZones( m_board.get() );
 
            BOOST_REQUIRE( zone->HasFilledPolysForLayer( F_Cu ) );
 
            const std::shared_ptr<SHAPE_POLY_SET>& fill = zone->GetFilledPolysList( F_Cu );
            std::shared_ptr<SHAPE>                 viaShape = via->GetEffectiveShape( F_Cu );
 
            // The zone fill must touch the via.  If it does not, the via is isolated copper
            // inside a hatch hole (the issue 24559 regression).
            if( !fill->Collide( viaShape.get(), 0 ) )
                isolatedCount++;
 
            testedCount++;
 
            m_board->Remove( via );
            m_board->Remove( zone );
            delete via;
            delete zone;
        }
    }
 
    BOOST_CHECK_MESSAGE( isolatedCount == 0, wxString::Format( "%d of %d FULL-connection via positions were left "
                                                               "isolated from the hatch fill (issue 24559).",
                                                               isolatedCount, testedCount ) );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionCascadingIslandRefill, ZONE_FILL_TEST_FIXTURE )
{
    ADVANCED_CFG& cfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
    bool          originalIterativeRefill = cfg.m_ZoneFillIterativeRefill;
    cfg.m_ZoneFillIterativeRefill = true;
 
    struct ScopeGuard
    {
        bool& ref;
        bool  orig;
        ~ScopeGuard() { ref = orig; }
    } guard{ cfg.m_ZoneFillIterativeRefill, originalIterativeRefill };
 
    KI_TEST::LoadBoard( m_settingsManager, "zone_refill_cascading_islands", m_board );
    KI_TEST::FillZones( m_board.get() );
 
    const std::vector<std::string> checkedNames = { "hi1", "hi2", "hi3", "hi4", "hi5", "hi6", "hi7",
                                                    "lo1", "lo2", "lo3", "lo4", "lo5", "lo6" };
    std::map<std::string, ZONE*>   zoneByName;
 
    for( ZONE* zone : m_board->Zones() )
        zoneByName[zone->GetZoneName().ToStdString()] = zone;
 
    for( const std::string& name : checkedNames )
    {
        BOOST_REQUIRE_MESSAGE( zoneByName.count( name ), "Zone '" + name + "' not found in test board" );
        BOOST_REQUIRE_MESSAGE( zoneByName[name]->HasFilledPolysForLayer( F_Cu ),
                               "Zone '" + name + "' has no fill on F.Cu" );
    }
 
    // hi3, hi5, hi7 each split into two copper islands (one standalone, one merged with lo2/lo4/lo6).
    for( const std::string& name : { "hi3", "hi5", "hi7" } )
    {
        int islands = zoneByName[name]->GetFilledPolysList( F_Cu )->OutlineCount();
 
        BOOST_CHECK_MESSAGE( islands == 2, wxString::Format( "Zone '%s' should have 2 filled islands but has %d. "
                                                             "Cascading island removal did not converge correctly.",
                                                             name, islands ) );
    }
 
    // All lo zones and hi2/hi4/hi6 are single zones.
    for( const std::string& name : { "lo1", "lo2", "lo3", "lo4", "lo5", "lo6", "hi2", "hi4", "hi6" } )
    {
        int islands = zoneByName[name]->GetFilledPolysList( F_Cu )->OutlineCount();
 
        BOOST_CHECK_MESSAGE( islands == 1, wxString::Format( "Zone '%s' should have 1 filled island but has %d. "
                                                             "Iterative refill may have incorrectly blocked or "
                                                             "expanded this zone.",
                                                             name, islands ) );
    }
}
 

BOOST_FIXTURE_TEST_CASE( CopperThievingZone_HatchSurvivesTrackBisection, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "zone_thieving_track_bisection", m_board );
    KI_TEST::FillZones( m_board.get() );
 
    ZONE* thievingZone = nullptr;
 
    for( ZONE* z : m_board->Zones() )
    {
        if( z->GetFillMode() == ZONE_FILL_MODE::COPPER_THIEVING )
        {
            thievingZone = z;
            break;
        }
    }
 
    BOOST_REQUIRE( thievingZone );
 
    const std::shared_ptr<SHAPE_POLY_SET>& fill = thievingZone->GetFilledPolysList( F_Cu );
    BOOST_REQUIRE( fill );
 
    // The track splits the fill area in two; before the fix the connectivity
    // pass classified the narrow side as an isolated island and deleted it.
    // Expect at least two outlines covering both halves of the original zone.
    BOOST_CHECK_GE( fill->OutlineCount(), 2 );
 
    // The fill must span the full zone width (left edge through right edge).
    BOX2I fillBox = fill->BBox();
    BOX2I zoneBox = thievingZone->Outline()->BBox();
 
    BOOST_CHECK_LT( fillBox.GetLeft(),   zoneBox.GetLeft()  + pcbIUScale.mmToIU( 2.0 ) );
    BOOST_CHECK_GT( fillBox.GetRight(),  zoneBox.GetRight() - pcbIUScale.mmToIU( 2.0 ) );
 
    // The mesh must have real structure on both sides.
    BOOST_CHECK_GT( fill->TotalVertices(), 200 );
}
 

BOOST_FIXTURE_TEST_CASE( IterativeRefillConvergenceLimit, ZONE_FILL_TEST_FIXTURE )
{
    ADVANCED_CFG& cfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
    bool          originalIterativeRefill = cfg.m_ZoneFillIterativeRefill;
    cfg.m_ZoneFillIterativeRefill = true;
 
    struct ScopeGuard
    {
        bool& ref;
        bool  orig;
        ~ScopeGuard() { ref = orig; }
    } guard{ cfg.m_ZoneFillIterativeRefill, originalIterativeRefill };
 
 
    KI_TEST::SCOPED_COUNTING_WXLOG countingLog( nullptr, wxLOG_Warning );
 
    KI_TEST::LoadBoard( m_settingsManager, "zone_refill_convergence_limit", m_board );
    KI_TEST::FillZones( m_board.get() );
 
    BOOST_CHECK_MESSAGE( countingLog.GetCount() > 0, "Expected a wxLogWarning when iterative refill hits the iteration "
                                                     "limit, but none was emitted.  The convergence-limit board may no "
                                                     "longer trigger the cap, or the warning path has changed." );
}
 

BOOST_FIXTURE_TEST_CASE( CopperThievingZone_NonCopperLayerStampsNotSolid, ZONE_FILL_TEST_FIXTURE )
{
    m_board = std::make_unique<BOARD>();
 
    ZONE* zone = new ZONE( m_board.get() );
    zone->SetLayer( F_SilkS );
    zone->AppendCorner( VECTOR2I( 0, 0 ), -1 );
    zone->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 10 ), 0 ), -1 );
    zone->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 10 ), pcbIUScale.mmToIU( 10 ) ), -1 );
    zone->AppendCorner( VECTOR2I( 0, pcbIUScale.mmToIU( 10 ) ), -1 );
    zone->SetFillMode( ZONE_FILL_MODE::COPPER_THIEVING );
 
    THIEVING_SETTINGS thieving;
    thieving.pattern      = THIEVING_PATTERN::DOTS;
    thieving.element_size = pcbIUScale.mmToIU( 0.5 );
    thieving.gap          = pcbIUScale.mmToIU( 1.5 );
    zone->SetThievingSettings( thieving );
    zone->SetIslandRemovalMode( ISLAND_REMOVAL_MODE::NEVER );
    m_board->Add( zone );
 
    KI_TEST::FillZones( m_board.get() );
 
    const std::shared_ptr<SHAPE_POLY_SET>& fill = zone->GetFilledPolysList( F_SilkS );
    BOOST_REQUIRE( fill );
 
    // A solid fill would have one outline (the zone polygon); a dots grid
    // produces dozens.  Lower bound is conservative to avoid edge-clipping flakiness.
    BOOST_CHECK_GT( fill->OutlineCount(), 5 );
}
 

BOOST_FIXTURE_TEST_CASE( CopperThievingZone_DotsGrid, ZONE_FILL_TEST_FIXTURE )
{
    m_board = std::make_unique<BOARD>();
    m_board->SetCopperLayerCount( 2 );
 
    // 10 mm x 10 mm zone outline
    ZONE* zone = new ZONE( m_board.get() );
    zone->SetLayer( F_Cu );
    zone->AppendCorner( VECTOR2I( 0, 0 ), -1 );
    zone->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 10 ), 0 ), -1 );
    zone->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 10 ), pcbIUScale.mmToIU( 10 ) ), -1 );
    zone->AppendCorner( VECTOR2I( 0, pcbIUScale.mmToIU( 10 ) ), -1 );
 
    zone->SetFillMode( ZONE_FILL_MODE::COPPER_THIEVING );
 
    THIEVING_SETTINGS thieving;
    thieving.pattern      = THIEVING_PATTERN::DOTS;
    thieving.element_size = pcbIUScale.mmToIU( 0.5 );
    thieving.gap        = pcbIUScale.mmToIU( 2.0 );
    thieving.line_width   = pcbIUScale.mmToIU( 0.3 );
    thieving.stagger      = false;
    thieving.orientation     = ANGLE_0;
    zone->SetThievingSettings( thieving );
 
    zone->SetIslandRemovalMode( ISLAND_REMOVAL_MODE::NEVER );
 
    m_board->Add( zone );
 
    KI_TEST::FillZones( m_board.get() );
 
    const std::shared_ptr<SHAPE_POLY_SET>& fill = zone->GetFilledPolysList( F_Cu );
    BOOST_REQUIRE( fill );
    BOOST_REQUIRE_GT( fill->OutlineCount(), 0 );
 
    // 2.5 mm pitch, 0.5 mm dot.  The four positions whose disc touches the
    // zone edge (x or y at 0 or 10 mm) are dropped, leaving a 3 x 3 grid.
    BOOST_CHECK_GE( fill->OutlineCount(), 6 );
    BOOST_CHECK_LE( fill->OutlineCount(), 12 );
 
    // 10% slack covers the polygonal circle approximation plus post-fill corner rounding.
    const double fullDotArea = M_PI * std::pow( pcbIUScale.mmToIU( 0.25 ), 2 );
    CheckAllOutlineAreasAtLeast( fill, 0.9 * fullDotArea, wxT( "Dot" ) );
}
 

BOOST_FIXTURE_TEST_CASE( CopperThievingZone_StaggerProducesDifferentLayout, ZONE_FILL_TEST_FIXTURE )
{
    auto countDots = []( bool stagger ) -> int
    {
        auto board = std::make_unique<BOARD>();
        board->SetCopperLayerCount( 2 );
 
        ZONE* zone = new ZONE( board.get() );
        zone->SetLayer( F_Cu );
        zone->AppendCorner( VECTOR2I( 0, 0 ), -1 );
        zone->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 20 ), 0 ), -1 );
        zone->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 20 ), pcbIUScale.mmToIU( 20 ) ), -1 );
        zone->AppendCorner( VECTOR2I( 0, pcbIUScale.mmToIU( 20 ) ), -1 );
        zone->SetFillMode( ZONE_FILL_MODE::COPPER_THIEVING );
 
        THIEVING_SETTINGS thieving;
        thieving.pattern      = THIEVING_PATTERN::DOTS;
        thieving.element_size = pcbIUScale.mmToIU( 0.5 );
        thieving.gap        = pcbIUScale.mmToIU( 2.0 );
        thieving.stagger      = stagger;
        zone->SetThievingSettings( thieving );
        zone->SetIslandRemovalMode( ISLAND_REMOVAL_MODE::NEVER );
        board->Add( zone );
 
        KI_TEST::FillZones( board.get() );
        return zone->GetFilledPolysList( F_Cu )->OutlineCount();
    };
 
    int plain     = countDots( false );
    int staggered = countDots( true );
 
    BOOST_TEST_MESSAGE( "plain dots: " << plain << "  staggered dots: " << staggered );
 
    // Within a factor of two — catches the offset walking dots off the board
    // (returning ~0) without being brittle about edge-clipping rounding.
    BOOST_CHECK_NE( plain, staggered );
    BOOST_CHECK_GE( staggered, plain / 2 );
    BOOST_CHECK_LE( staggered, plain * 2 );
}
 

BOOST_FIXTURE_TEST_CASE( CopperThievingZone_SquaresGrid, ZONE_FILL_TEST_FIXTURE )
{
    m_board = std::make_unique<BOARD>();
    m_board->SetCopperLayerCount( 2 );
 
    ZONE* zone = new ZONE( m_board.get() );
    zone->SetLayer( F_Cu );
    zone->AppendCorner( VECTOR2I( 0, 0 ), -1 );
    zone->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 10 ), 0 ), -1 );
    zone->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 10 ), pcbIUScale.mmToIU( 10 ) ), -1 );
    zone->AppendCorner( VECTOR2I( 0, pcbIUScale.mmToIU( 10 ) ), -1 );
    zone->SetFillMode( ZONE_FILL_MODE::COPPER_THIEVING );
 
    THIEVING_SETTINGS thieving;
    thieving.pattern      = THIEVING_PATTERN::SQUARES;
    thieving.element_size = pcbIUScale.mmToIU( 0.6 );
    thieving.gap        = pcbIUScale.mmToIU( 2.0 );
    zone->SetThievingSettings( thieving );
    zone->SetIslandRemovalMode( ISLAND_REMOVAL_MODE::NEVER );
    m_board->Add( zone );
 
    KI_TEST::FillZones( m_board.get() );
 
    const std::shared_ptr<SHAPE_POLY_SET>& fill = zone->GetFilledPolysList( F_Cu );
    BOOST_REQUIRE( fill );
    BOOST_REQUIRE_GT( fill->OutlineCount(), 0 );
 
    // 2.6 mm pitch, 0.6 mm square.  Same edge-drop behavior as the dots test:
    // strict-containment leaves a 3 x 3 grid of full squares.
    BOOST_CHECK_GE( fill->OutlineCount(), 6 );
    BOOST_CHECK_LE( fill->OutlineCount(), 12 );
 
    const double fullSquareArea = std::pow( pcbIUScale.mmToIU( 0.6 ), 2 );
    CheckAllOutlineAreasAtLeast( fill, 0.9 * fullSquareArea, wxT( "Square" ) );
}
 

BOOST_FIXTURE_TEST_CASE( CopperThievingZone_HighDensityPerformance, ZONE_FILL_TEST_FIXTURE )
{
    m_board = std::make_unique<BOARD>();
    m_board->SetCopperLayerCount( 2 );
 
    ZONE* zone = new ZONE( m_board.get() );
    zone->SetLayer( F_Cu );
    zone->AppendCorner( VECTOR2I( 0, 0 ), -1 );
    zone->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 100 ), 0 ), -1 );
    zone->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 100 ), pcbIUScale.mmToIU( 100 ) ), -1 );
    zone->AppendCorner( VECTOR2I( 0, pcbIUScale.mmToIU( 100 ) ), -1 );
    zone->SetFillMode( ZONE_FILL_MODE::COPPER_THIEVING );
 
    THIEVING_SETTINGS thieving;
    thieving.pattern      = THIEVING_PATTERN::DOTS;
    thieving.element_size = pcbIUScale.mmToIU( 0.3 );
    thieving.gap          = pcbIUScale.mmToIU( 1.0 );
    zone->SetThievingSettings( thieving );
    zone->SetIslandRemovalMode( ISLAND_REMOVAL_MODE::NEVER );
    m_board->Add( zone );
 
    auto start = std::chrono::steady_clock::now();
    KI_TEST::FillZones( m_board.get() );
    auto elapsed = std::chrono::duration_cast<std::chrono::milliseconds>(
                           std::chrono::steady_clock::now() - start )
                           .count();
 
    BOOST_TEST_MESSAGE( "5.9k-dot fill elapsed: " << elapsed << " ms" );
 
    BOOST_REQUIRE( zone->GetFilledPolysList( F_Cu ) );
    BOOST_CHECK_GT( zone->GetFilledPolysList( F_Cu )->OutlineCount(), 4000 );
 
    // Sanitizer instrumentation changes execution cost, not the fill contract
#if !defined( KICAD_SANITIZE_THREADS ) && !defined( KICAD_SANITIZE_ADDRESS )
    // 30 s upper bound on QABUILD with assertions on; current implementation
    // measures in low seconds.
    BOOST_CHECK_LT( elapsed, 30000 );
#endif
}
 

BOOST_FIXTURE_TEST_CASE( CopperThievingZone_HatchPattern, ZONE_FILL_TEST_FIXTURE )
{
    m_board = std::make_unique<BOARD>();
    m_board->SetCopperLayerCount( 2 );
 
    ZONE* zone = new ZONE( m_board.get() );
    zone->SetLayer( F_Cu );
    zone->AppendCorner( VECTOR2I( 0, 0 ), -1 );
    zone->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 10 ), 0 ), -1 );
    zone->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 10 ), pcbIUScale.mmToIU( 10 ) ), -1 );
    zone->AppendCorner( VECTOR2I( 0, pcbIUScale.mmToIU( 10 ) ), -1 );
    zone->SetFillMode( ZONE_FILL_MODE::COPPER_THIEVING );
 
    THIEVING_SETTINGS thieving;
    thieving.pattern    = THIEVING_PATTERN::HATCH;
    thieving.gap        = pcbIUScale.mmToIU( 2.0 );
    thieving.line_width = pcbIUScale.mmToIU( 0.3 );
    zone->SetThievingSettings( thieving );
    zone->SetIslandRemovalMode( ISLAND_REMOVAL_MODE::NEVER );
    m_board->Add( zone );
 
    KI_TEST::FillZones( m_board.get() );
 
    const std::shared_ptr<SHAPE_POLY_SET>& fill = zone->GetFilledPolysList( F_Cu );
    BOOST_REQUIRE( fill );
    BOOST_REQUIRE_GT( fill->TotalVertices(), 0 );
 
    // Subtractive hatch produces a single connected outline after fracturing
    // (perimeter border + interior mesh linked through bridges).  A dot grid
    // in the same outline would have dozens of disconnected pieces.
    BOOST_CHECK_EQUAL( fill->OutlineCount(), 1 );
 
    // The fill bounding box must reach the zone corners — the perimeter
    // border is what differentiates hatch from a dot grid.  Solid would also
    // reach the corners; the high vertex count below catches that case.
    BOX2I fillBox = fill->BBox();
    BOOST_CHECK_LT( fillBox.GetLeft(),   pcbIUScale.mmToIU( 0.5 ) );
    BOOST_CHECK_GT( fillBox.GetRight(),  pcbIUScale.mmToIU( 9.5 ) );
    BOOST_CHECK_LT( fillBox.GetTop(),    pcbIUScale.mmToIU( 0.5 ) );
    BOOST_CHECK_GT( fillBox.GetBottom(), pcbIUScale.mmToIU( 9.5 ) );
 
    // A solid 10x10 mm rectangle would have ~4 vertices.  A hatched mesh has
    // many vertices because each void cut adds outline segments.
    BOOST_CHECK_GT( fill->TotalVertices(), 30 );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionNonCopperZoneKeepoutIslands, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue24089/issue24089", m_board );
 
    auto countIslands =
            [this]() -> int
            {
                int total = 0;
 
                for( ZONE* zone : m_board->Zones() )
                {
                    if( zone->GetIsRuleArea() )
                        continue;
 
                    for( PCB_LAYER_ID layer : zone->GetLayerSet().Seq() )
                    {
                        if( !zone->HasFilledPolysForLayer( layer ) )
                            continue;
 
                        std::shared_ptr<SHAPE_POLY_SET> fill = zone->GetFilledPolysList( layer );
 
                        if( fill )
                            total += fill->OutlineCount();
                    }
                }
 
                return total;
            };
 
    int storedIslands = countIslands();
 
    BOOST_REQUIRE_MESSAGE( storedIslands >= 3,
                           wxString::Format( "Stored v9 fill should have at least 3 silk islands; "
                                             "found %d",
                                             storedIslands ) );
 
    KI_TEST::FillZones( m_board.get() );
 
    int refilledIslands = countIslands();
 
    BOOST_CHECK_MESSAGE( refilledIslands == storedIslands,
                         wxString::Format( "Refill lost silk islands: stored=%d, refilled=%d. "
                                           "Outline 0 of every non-copper multi-island zone "
                                           "was being incorrectly removed (issue 24089).",
                                           storedIslands, refilledIslands ) );
}
 

BOOST_FIXTURE_TEST_CASE( OverlappingPriorityPadFlashing, ZONE_FILL_TEST_FIXTURE )
{
    m_board = std::make_unique<BOARD>();
    m_board->SetCopperLayerCount( 4 );
 
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
    bds.SetCopperLayerCount( 4 );
    bds.m_MinClearance = pcbIUScale.mmToIU( 0.2 );
 
    NETINFO_ITEM* gndNet = new NETINFO_ITEM( m_board.get(), wxT( "GND" ) );
    m_board->Add( gndNet );
    int gndNetCode = gndNet->GetNetCode();
 
    NETINFO_ITEM* vccNet = new NETINFO_ITEM( m_board.get(), wxT( "VCC" ) );
    m_board->Add( vccNet );
    int vccNetCode = vccNet->GetNetCode();
 
    ZONE* gndZone = new ZONE( m_board.get() );
    gndZone->SetLayer( In1_Cu );
    gndZone->SetNetCode( gndNetCode );
    gndZone->SetAssignedPriority( 0 );
    gndZone->SetMinThickness( pcbIUScale.mmToIU( 0.2 ) );
    gndZone->SetThermalReliefGap( pcbIUScale.mmToIU( 0.5 ) );
    gndZone->SetThermalReliefSpokeWidth( pcbIUScale.mmToIU( 0.5 ) );
    gndZone->SetPadConnection( ZONE_CONNECTION::THERMAL );
    {
        SHAPE_POLY_SET outline;
        outline.NewOutline();
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 0 ),  pcbIUScale.mmToIU( 0 ) ) );
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 30 ), pcbIUScale.mmToIU( 0 ) ) );
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 30 ), pcbIUScale.mmToIU( 20 ) ) );
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 0 ),  pcbIUScale.mmToIU( 20 ) ) );
        gndZone->AddPolygon( outline.COutline( 0 ) );
    }
    m_board->Add( gndZone );
 
    ZONE* vccZone = new ZONE( m_board.get() );
    vccZone->SetLayer( In1_Cu );
    vccZone->SetNetCode( vccNetCode );
    vccZone->SetAssignedPriority( 5 );
    vccZone->SetMinThickness( pcbIUScale.mmToIU( 4.0 ) );
    vccZone->SetThermalReliefGap( pcbIUScale.mmToIU( 0.5 ) );
    vccZone->SetThermalReliefSpokeWidth( pcbIUScale.mmToIU( 0.5 ) );
    vccZone->SetPadConnection( ZONE_CONNECTION::FULL );
    {
        // A "barbell": a bulky right lobe joined to a thin left neck by a 0.5mm-tall corridor.
        // VCC's 4mm min-thickness prunes the neck and corridor in the deflate/inflate pass, so
        // VCC fills only the right lobe while its outline still encloses the pad at (15, 10).
        SHAPE_POLY_SET outline;
        outline.NewOutline();
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 13.5 ), pcbIUScale.mmToIU( 9.75 ) ) );
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 18 ),   pcbIUScale.mmToIU( 9.75 ) ) );
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 18 ),   pcbIUScale.mmToIU( 0 ) ) );
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 30 ),   pcbIUScale.mmToIU( 0 ) ) );
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 30 ),   pcbIUScale.mmToIU( 20 ) ) );
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 18 ),   pcbIUScale.mmToIU( 20 ) ) );
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 18 ),   pcbIUScale.mmToIU( 10.25 ) ) );
        outline.Append( VECTOR2I( pcbIUScale.mmToIU( 13.5 ), pcbIUScale.mmToIU( 10.25 ) ) );
        vccZone->AddPolygon( outline.COutline( 0 ) );
    }
    m_board->Add( vccZone );
 
    // REMOVE_EXCEPT_START_AND_END makes inner-layer flashing conditional on a same-net
    // connection, which is what issue 24175 gets wrong.
    auto footprint = std::make_unique<FOOTPRINT>( m_board.get() );
 
    PAD* pad = new PAD( footprint.get() );
    pad->SetPadstackMode( PADSTACK::MODE::NORMAL );
    pad->SetAttribute( PAD_ATTRIB::PTH );
    pad->SetLayerSet( LSET::AllCuMask() );
    pad->SetSize( PADSTACK::ALL_LAYERS, VECTOR2I( pcbIUScale.mmToIU( 1.5 ), pcbIUScale.mmToIU( 1.5 ) ) );
    pad->SetDrillSize( VECTOR2I( pcbIUScale.mmToIU( 0.8 ), pcbIUScale.mmToIU( 0.8 ) ) );
    pad->SetPosition( VECTOR2I( pcbIUScale.mmToIU( 15 ), pcbIUScale.mmToIU( 10 ) ) );
    pad->SetUnconnectedLayerMode( UNCONNECTED_LAYER_MODE::REMOVE_EXCEPT_START_AND_END );
    pad->SetNetCode( gndNetCode );
 
    footprint->Add( pad );
    footprint->SetPosition( VECTOR2I( 0, 0 ) );
    m_board->Add( footprint.release() );
 
    m_board->BuildConnectivity();
    auto drcEngine = std::make_shared<DRC_ENGINE>( m_board.get(), &bds );
    drcEngine->InitEngine( wxFileName() );
    bds.m_DRCEngine = drcEngine;
 
    KI_TEST::FillZones( m_board.get() );
 
    // Guard the preconditions so a future fill change cannot make this pass for the wrong
    // reason: VCC's outline must enclose the pad while its fill must not reach it.
    BOOST_REQUIRE_MESSAGE( vccZone->Outline()->Contains( pad->GetPosition() ),
                           "VCC outline must contain the pad position to reproduce issue 24175." );
    BOOST_REQUIRE_MESSAGE( vccZone->HasFilledPolysForLayer( In1_Cu ),
                           "VCC zone should still have fill in its right lobe." );
 
    {
        const std::shared_ptr<SHAPE_POLY_SET>& vccFill = vccZone->GetFilledPolysList( In1_Cu );
 
        BOOST_REQUIRE_MESSAGE( !vccFill->Contains( pad->GetPosition() ),
                               "VCC fill should NOT contain the pad position (corridor must be "
                               "pruned by min-thickness for the test to exercise issue 24175)." );
    }
 
    // Before the fix the higher-priority VCC outline forced ZLO_FORCE_NO_ZONE_CONNECTION on
    // the pad; now the same-net GND zone wins the flashing decision.
    BOOST_CHECK_MESSAGE( pad->FlashLayer( In1_Cu ),
                         "PTH pad inside higher-priority different-net zone must still flash "
                         "when a same-net lower-priority zone covers it (issue 24175)." );
 
    BOOST_REQUIRE_MESSAGE( gndZone->HasFilledPolysForLayer( In1_Cu ),
                           "GND zone should have fill on In1.Cu" );
 
    const std::shared_ptr<SHAPE_POLY_SET>& gndFill = gndZone->GetFilledPolysList( In1_Cu );
 
    // Sampling a ring just outside the pad proves the GND fill actually surrounds it.
    int  samples = 16;
    int  sampleR = pcbIUScale.mmToIU( 1.6 );  // just outside the pad (radius 0.75) + clearance
    bool foundCopperAround = false;
 
    for( int i = 0; i < samples; i++ )
    {
        double   angle = ( 2.0 * M_PI * i ) / samples;
        VECTOR2I p( pad->GetPosition().x + KiROUND( sampleR * std::cos( angle ) ),
                    pad->GetPosition().y + KiROUND( sampleR * std::sin( angle ) ) );
 
        if( gndFill->Contains( p ) )
        {
            foundCopperAround = true;
            break;
        }
    }
 
    BOOST_CHECK_MESSAGE( foundCopperAround,
                         "Lower-priority GND zone should have copper around GND pad even when "
                         "a higher-priority different-net zone outline contains the pad "
                         "(issue 24175)." );
}
 
 
// Reproduces the scripting/API zone-fill path used by KiKit panelization (issue 24643).
//
// The interactive GUI and the board loader always create and initialize the board's DRC engine
// before filling.  The Python/API ZONE_FILLER path can reach Fill() with no engine, so the
// worker-thread EvalRules() calls dereferenced a null engine and crashed the process.  This test
// drops the engine after loading to drive that path, then verifies Fill() completes and leaves a
// usable engine behind.
BOOST_FIXTURE_TEST_CASE( RegressionApiSubsetFillPanelized, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue24643/issue24643", m_board );
 
    // The test harness loads boards with an initialized engine; the headless API path does not.
    // Drop it so Fill() must reconstruct one, which is the condition that crashed.
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
    bds.m_DRCEngine.reset();
    BOOST_REQUIRE( !bds.m_DRCEngine );
 
    // Mirror the script: select non-rule-area zones on B.Cu that are not already filled.
    PCB_LAYER_ID       targetLayer = m_board->GetLayerID( wxT( "B.Cu" ) );
    std::vector<ZONE*> toFill;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( zone->GetIsRuleArea() )
            continue;
 
        if( !zone->IsOnLayer( targetLayer ) )
            continue;
 
        if( zone->IsFilled() )
            continue;
 
        toFill.push_back( zone );
    }
 
    BOOST_REQUIRE_MESSAGE( !toFill.empty(),
                           "Expected at least one unfilled B.Cu zone to exercise the API path." );
 
    // The API path builds the filler with a null commit (see new_ZONE_FILLER in the SWIG
    // wrapper) and fills only the selected subset.  This must complete without crashing
    // (issue 24643).
    ZONE_FILLER filler( m_board.get(), nullptr );
 
    BOOST_CHECK_NO_THROW( filler.Fill( toFill ) );
 
    // Fill() must have created and initialized a usable engine in place of the one we dropped.
    BOOST_REQUIRE( bds.m_DRCEngine );
    BOOST_CHECK( bds.m_DRCEngine->RulesValid() );
}
 
 
// Issue 23790: overlapping same-net zones must merge across a notch a higher-priority
// different-net zone carved into the higher-priority same-net zone.
BOOST_FIXTURE_TEST_CASE( RegressionSameNetMergeAroundHigherPriorityZone, ZONE_FILL_TEST_FIXTURE )
{
    // The reconciliation only runs inside the iterative refill.
    ADVANCED_CFG& cfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
 
    struct ScopeGuard
    {
        bool& ref;
        bool  orig;
        ~ScopeGuard() { ref = orig; }
    } guard{ cfg.m_ZoneFillIterativeRefill, cfg.m_ZoneFillIterativeRefill };
 
    cfg.m_ZoneFillIterativeRefill = true;
 
    KI_TEST::LoadBoard( m_settingsManager, "issue23790/issue23790", m_board );
    KI_TEST::FillZones( m_board.get() );
 
    const PCB_LAYER_ID layer = F_Cu;
    const int          margin = pcbIUScale.mmToIU( 0.05 );
 
    std::map<int, SHAPE_POLY_SET> mergedByNet;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( zone->GetIsRuleArea() || !zone->HasFilledPolysForLayer( layer ) )
            continue;
 
        mergedByNet[zone->GetNetCode()].BooleanAdd( *zone->GetFilledPolysList( layer ) );
    }
 
    // Areas legitimately free of this net's copper: keepouts and higher-priority
    // different-net fills (grown by a clearance allowance).
    auto buildLegitVoids =
            [&]( const ZONE* aLower, const ZONE* aHigher ) -> SHAPE_POLY_SET
            {
                SHAPE_POLY_SET voids;
                int            allowance = pcbIUScale.mmToIU( 0.6 );
 
                for( ZONE* other : m_board->Zones() )
                {
                    if( !other->GetLayerSet().Contains( layer ) )
                        continue;
 
                    if( other->GetIsRuleArea() )
                    {
                        if( other->GetDoNotAllowZoneFills() )
                            voids.BooleanAdd( *other->Outline() );
 
                        continue;
                    }
 
                    if( other->GetNetCode() == aLower->GetNetCode()
                            || other->GetAssignedPriority() <= aLower->GetAssignedPriority()
                            || other->GetAssignedPriority() <= aHigher->GetAssignedPriority()
                            || !other->HasFilledPolysForLayer( layer ) )
                    {
                        continue;
                    }
 
                    SHAPE_POLY_SET fill = *other->GetFilledPolysList( layer );
                    fill.Inflate( allowance, CORNER_STRATEGY::ROUND_ALL_CORNERS, ARC_HIGH_DEF );
                    voids.BooleanAdd( fill );
                }
 
                return voids;
            };
 
    std::vector<ZONE*> zones;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( !zone->GetIsRuleArea() && zone->GetNetCode() > 0 && zone->GetLayerSet().Contains( layer ) )
            zones.push_back( zone );
    }
 
    int checkedPairs = 0;
 
    for( size_t i = 0; i < zones.size(); ++i )
    {
        for( size_t j = i + 1; j < zones.size(); ++j )
        {
            ZONE* a = zones[i];
            ZONE* b = zones[j];
 
            if( a->GetNetCode() != b->GetNetCode() )
                continue;
 
            SHAPE_POLY_SET overlap = *a->Outline();
            overlap.BooleanIntersection( *b->Outline() );
 
            if( overlap.OutlineCount() == 0 )
                continue;
 
            const ZONE* lower = a->GetAssignedPriority() <= b->GetAssignedPriority() ? a : b;
            const ZONE* higher = ( lower == a ) ? b : a;
 
            overlap.BooleanSubtract( buildLegitVoids( lower, higher ) );
 
            // Stay clear of outer-boundary min-width rounding.
            overlap.Deflate( margin, CORNER_STRATEGY::CHAMFER_ALL_CORNERS, ARC_HIGH_DEF );
 
            if( overlap.OutlineCount() == 0 )
                continue;
 
            SHAPE_POLY_SET uncovered = overlap;
            uncovered.BooleanSubtract( mergedByNet[a->GetNetCode()] );
 
            double uncoveredArea =
                    uncovered.Area() / ( pcbIUScale.IU_PER_MM * (double) pcbIUScale.IU_PER_MM );
 
            BOOST_CHECK_MESSAGE( uncoveredArea < 0.01,
                    wxString::Format( "Same-net zones (priorities %d and %d) left %.4f mm^2 of "
                                      "their overlap unfilled; overlapping same-net zones must "
                                      "merge (issue 23790).",
                                      a->GetAssignedPriority(), b->GetAssignedPriority(),
                                      uncoveredArea ) );
            checkedPairs++;
        }
    }
 
    BOOST_CHECK_MESSAGE( checkedPairs >= 2,
                         wxString::Format( "Expected at least two overlapping same-net zone pairs "
                                           "to exercise the merge, found %d.", checkedPairs ) );
}
 
 
// Issue 24935: a lower-priority same-net zone must not pour through the hatch windows of a
// higher-priority hatched zone during the iterative refill.
BOOST_FIXTURE_TEST_CASE( RegressionHatchedZonePriorityRefill, ZONE_FILL_TEST_FIXTURE )
{
    ADVANCED_CFG& cfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
 
    struct ScopeGuard
    {
        bool& ref;
        bool  orig;
        ~ScopeGuard() { ref = orig; }
    } guard{ cfg.m_ZoneFillIterativeRefill, cfg.m_ZoneFillIterativeRefill };
 
    for( bool iterative : { true, false } )
    {
        cfg.m_ZoneFillIterativeRefill = iterative;
 
        KI_TEST::LoadBoard( m_settingsManager, "issue24935/issue24935", m_board );
        KI_TEST::FillZones( m_board.get() );
 
        const PCB_LAYER_ID layer = F_Cu;
        ZONE*              hatched = nullptr;
        ZONE*              solid = nullptr;
 
        for( ZONE* zone : m_board->Zones() )
        {
            if( zone->GetFillMode() == ZONE_FILL_MODE::HATCH_PATTERN )
                hatched = zone;
            else
                solid = zone;
        }
 
        BOOST_REQUIRE( hatched && solid );
        BOOST_REQUIRE( hatched->GetAssignedPriority() > solid->GetAssignedPriority() );
        BOOST_REQUIRE( hatched->SameNet( solid ) );
        BOOST_REQUIRE( hatched->HasFilledPolysForLayer( layer ) );
        BOOST_REQUIRE( solid->HasFilledPolysForLayer( layer ) );
 
        const double mm2 = pcbIUScale.IU_PER_MM * (double) pcbIUScale.IU_PER_MM;
 
        // Guard against a degenerate fixture: the hatch must leave most of its outline open,
        // otherwise the containment check below proves nothing.
        SHAPE_POLY_SET hatchedFill = hatched->GetFilledPolysList( layer )->CloneDropTriangulation();
        SHAPE_POLY_SET hatchedOutline = hatched->Outline()->CloneDropTriangulation();
        BOOST_REQUIRE( hatchedFill.Area() < 0.8 * hatchedOutline.Area() );
 
        // The lower-priority zone owns nothing inside the hatched zone's outline.
        SHAPE_POLY_SET window = hatchedOutline;
        window.Deflate( pcbIUScale.mmToIU( 0.05 ), CORNER_STRATEGY::CHAMFER_ALL_CORNERS, ARC_HIGH_DEF );
 
        SHAPE_POLY_SET leaked = solid->GetFilledPolysList( layer )->CloneDropTriangulation();
        leaked.BooleanIntersection( window );
 
        double leakedArea = leaked.Area() / mm2;
 
        BOOST_CHECK_MESSAGE( leakedArea < 0.01,
                             wxString::Format( "%s: lower-priority zone poured %.3f mm^2 inside the "
                                               "higher-priority hatched zone (issue 24935).",
                                               iterative ? wxS( "iterative refill" ) : wxS( "single pass" ),
                                               leakedArea ) );
    }
}
 
 
// Issue 24758: this board is densely tiled with same-net zones, so the zone-fill dependency-DAG
// scheduler builds a large successor graph.  The scheduler returned once its logical work counter
// reached zero while detached worker tasks -- which captured the successor/in-degree vectors by
// reference -- were still in flight, dereferencing the freed locals inside ZONE_FILLER::Fill.
// Filling repeatedly drives that window; under AddressSanitizer the use-after-free is reported
// deterministically without the fix.
BOOST_FIXTURE_TEST_CASE( RegressionSameNetZoneFillScheduler, ZONE_FILL_TEST_FIXTURE )
{
    ADVANCED_CFG& cfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
 
    struct ScopeGuard
    {
        bool& ref;
        bool  orig;
        ~ScopeGuard() { ref = orig; }
    } guard{ cfg.m_ZoneFillIterativeRefill, cfg.m_ZoneFillIterativeRefill };
 
    cfg.m_ZoneFillIterativeRefill = true;
 
    KI_TEST::LoadBoard( m_settingsManager, "issue24758/issue24758", m_board );
 
    const PCB_LAYER_ID layer = F_Cu;
 
    for( int pass = 0; pass < 64; ++pass )
    {
        BOOST_REQUIRE_NO_THROW( KI_TEST::FillZones( m_board.get() ) );
 
        // Every same-net pour must come back with copper; a torn-down scheduler also corrupts
        // or drops fills, so assert the result is usable on every pass.
        SHAPE_POLY_SET merged;
 
        for( ZONE* zone : m_board->Zones() )
        {
            if( zone->GetIsRuleArea() || !zone->HasFilledPolysForLayer( layer ) )
                continue;
 
            std::shared_ptr<SHAPE_POLY_SET> fill = zone->GetFilledPolysList( layer );
 
            BOOST_REQUIRE( fill != nullptr );
            merged.BooleanAdd( *fill );
        }
 
        BOOST_CHECK_MESSAGE( merged.Area() > 0.0,
                             wxString::Format( "Fill pass %d produced no copper.", pass ) );
    }
}
 
 
// Issue 24758: a hatch zone must keep its solid border where a higher-priority zone carves into
// it, not run the mesh into the carved edge.  Board issue24758 carves net-B zones into net-A hatch.
BOOST_FIXTURE_TEST_CASE( RegressionHatchBorderAroundOverlap, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue24758/issue24758", m_board );
    KI_TEST::FillZones( m_board.get() );
 
    const PCB_LAYER_ID layer = F_Cu;
 
    auto outlineNoArcs =
            []( ZONE* z )
            {
                SHAPE_POLY_SET o = *z->Outline();
                o.ClearArcs();
                return o;
            };
 
    int checkedPairs = 0;
 
    for( ZONE* hatch : m_board->Zones() )
    {
        if( hatch->GetIsRuleArea() || hatch->GetFillMode() != ZONE_FILL_MODE::HATCH_PATTERN
                || !hatch->HasFilledPolysForLayer( layer ) )
        {
            continue;
        }
 
        SHAPE_POLY_SET hatchOutline = outlineNoArcs( hatch );
        SHAPE_POLY_SET fill = *hatch->GetFilledPolysList( layer );
 
        for( ZONE* other : m_board->Zones() )
        {
            if( other == hatch || other->GetIsRuleArea() || !other->GetLayerSet().Contains( layer )
                    || other->GetAssignedPriority() <= hatch->GetAssignedPriority() )
            {
                continue;
            }
 
            SHAPE_POLY_SET carved = outlineNoArcs( other );
            carved.BooleanIntersection( hatchOutline );
 
            // Need real claimed area to have a border to test.
            if( carved.Area() < pcbIUScale.mmToIU( 0.1 ) * (double) pcbIUScale.mmToIU( 0.1 ) )
                continue;
 
            // Ring past the clearance void: solid with the border, ~half hatch holes without it.
            SHAPE_POLY_SET outer = carved;
            outer.Inflate( pcbIUScale.mmToIU( 0.35 ), CORNER_STRATEGY::ROUND_ALL_CORNERS, ARC_HIGH_DEF );
 
            SHAPE_POLY_SET inner = carved;
            inner.Inflate( pcbIUScale.mmToIU( 0.20 ), CORNER_STRATEGY::ROUND_ALL_CORNERS, ARC_HIGH_DEF );
 
            SHAPE_POLY_SET band = outer;
            band.BooleanSubtract( inner );
            band.BooleanIntersection( hatchOutline );
 
            if( band.Area() <= 0 )
                continue;
 
            SHAPE_POLY_SET covered = band;
            covered.BooleanIntersection( fill );
 
            double coverage = covered.Area() / band.Area();
            checkedPairs++;
 
            BOOST_CHECK_MESSAGE( coverage >= 0.85,
                    wxString::Format( "Hatch zone %s carved by %s: border ring only %.0f%% filled; "
                                      "the hatch border was not re-established around the carved "
                                      "area (issue 24758).",
                                      hatch->GetZoneName(), other->GetZoneName(),
                                      coverage * 100.0 ) );
        }
    }
 
    BOOST_CHECK_MESSAGE( checkedPairs >= 3,
                         wxString::Format( "Expected at least three carved hatch borders to check, "
                                           "found %d.", checkedPairs ) );
}
 
 
// A pair separated by more than the clearance but less than the knockout reach used to fill
// unordered, so the knocked-out copper depended on which task finished first.
BOOST_FIXTURE_TEST_CASE( ZoneFillDependencyKnockoutMargin, ZONE_FILL_TEST_FIXTURE )
{
    m_board = std::make_unique<BOARD>();
 
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
    const int              clearance = pcbIUScale.mmToIU( 2 );
 
    // Also the board's worst clearance, so the separation below lands between the worst
    // clearance and the knockout reach.
    bds.m_NetSettings->GetDefaultNetclass()->SetClearance( clearance );
 
    NETINFO_ITEM* netA = new NETINFO_ITEM( m_board.get(), wxT( "NET_A" ), 1 );
    NETINFO_ITEM* netB = new NETINFO_ITEM( m_board.get(), wxT( "NET_B" ), 2 );
    m_board->Add( netA );
    m_board->Add( netB );
 
    // Separation lands inside the max-error part of the reach, so the gate's error term and
    // the fill ordering are both exercised.
    const int extraMargin = pcbIUScale.mmToIU( ADVANCED_CFG::GetCfg().m_ExtraClearance );
    const int maxError = bds.m_MaxError;
    const int sep = clearance + extraMargin + maxError / 2;
    const int ax = pcbIUScale.mmToIU( 100 ) + sep;
 
    ZONE* zoneA = new ZONE( m_board.get() );
    zoneA->SetLayer( F_Cu );
    zoneA->SetNet( netA );
    zoneA->SetAssignedPriority( 0 );
    zoneA->AppendCorner( VECTOR2I( ax, 0 ), -1 );
    zoneA->AppendCorner( VECTOR2I( ax + pcbIUScale.mmToIU( 2 ), 0 ), -1 );
    zoneA->AppendCorner( VECTOR2I( ax + pcbIUScale.mmToIU( 2 ), pcbIUScale.mmToIU( 10 ) ), -1 );
    zoneA->AppendCorner( VECTOR2I( ax, pcbIUScale.mmToIU( 10 ) ), -1 );
    m_board->Add( zoneA );
 
    // The sawtooth keeps this fill busy long enough that, without a dependency edge, the
    // small zone (seeded first) reliably fills before this fill publishes.
    ZONE* zoneB = new ZONE( m_board.get() );
    zoneB->SetLayer( F_Cu );
    zoneB->SetNet( netB );
    zoneB->SetAssignedPriority( 1 );
    zoneB->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 1 ), 0 ), -1 );
    zoneB->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 100 ), 0 ), -1 );
    zoneB->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 100 ), pcbIUScale.mmToIU( 100 ) ), -1 );
    zoneB->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 1 ), pcbIUScale.mmToIU( 100 ) ), -1 );
 
    for( int ii = 0; ii < 1000; ++ii )
    {
        int yTop = pcbIUScale.mmToIU( 100 ) - ii * pcbIUScale.mmToIU( 0.1 );
 
        zoneB->AppendCorner( VECTOR2I( 0, yTop - pcbIUScale.mmToIU( 0.05 ) ), -1 );
        zoneB->AppendCorner( VECTOR2I( pcbIUScale.mmToIU( 1 ), yTop - pcbIUScale.mmToIU( 0.1 ) ), -1 );
    }
 
    m_board->Add( zoneB );
 
    KI_TEST::FillZones( m_board.get() );
 
    std::shared_ptr<SHAPE_POLY_SET> fillA = zoneA->GetFilledPolysList( F_Cu );
    std::shared_ptr<SHAPE_POLY_SET> fillB = zoneB->GetFilledPolysList( F_Cu );
 
    BOOST_REQUIRE( fillA && fillA->OutlineCount() > 0 );
    BOOST_REQUIRE( fillB && fillB->OutlineCount() > 0 );
 
    // Threshold sits between the knocked-out gap and the un-knocked outline separation, so the
    // check distinguishes an ordered fill from a raced one.
    BOOST_CHECK_MESSAGE( !fillA->Collide( fillB.get(), clearance + extraMargin + maxError * 3 / 4 ),
                         "Lower-priority zone filled before the higher-priority knockout was "
                         "published; the fill depends on thread scheduling." );
}
 

BOOST_FIXTURE_TEST_CASE( RegressionZoneFillNarrowBridge, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue24312/issue24312", m_board );
 
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
 
    // Force connection-width severity so the regression assertion does not silently
    // weaken if the reproduction project is updated to ignore this code.
    bds.m_DRCSeverities[ DRCE_CONNECTION_WIDTH ] = SEVERITY::RPT_SEVERITY_ERROR;
 
    KI_TEST::FillZones( m_board.get() );
 
    std::vector<DRC_ITEM> violations;
 
    bds.m_DRCEngine->SetViolationHandler(
            [&]( const std::shared_ptr<DRC_ITEM>& aItem, const VECTOR2I& aPos, int aLayer,
                 const std::function<void( PCB_MARKER* )>& aPathGenerator )
            {
                if( aItem->GetErrorCode() == DRCE_CONNECTION_WIDTH )
                    violations.push_back( *aItem );
            } );
 
    bds.m_DRCEngine->RunTests( EDA_UNITS::MM, true, false );
 
    if( !violations.empty() )
    {
        UNITS_PROVIDER unitsProvider( pcbIUScale, EDA_UNITS::MM );
 
        BOARD_RC_ITEM_RESOLVER resolver( *m_board );
 
        for( const DRC_ITEM& item : violations )
            BOOST_TEST_MESSAGE( item.ShowReport( &unitsProvider, RPT_SEVERITY_ERROR, resolver ) );
    }
 
    BOOST_CHECK_MESSAGE( violations.empty(),
                         wxString::Format( "Zone fill produced %zu connection_width violations; "
                                           "expected 0 (issue 24312).",
                                           violations.size() ) );
}
 
 
BOOST_FIXTURE_TEST_CASE( RegressionIterativeRefillFullWidthBridge, ZONE_FILL_TEST_FIXTURE )
{
    ADVANCED_CFG& cfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
    bool          originalIterativeRefill = cfg.m_ZoneFillIterativeRefill;
 
    struct ScopeGuard
    {
        bool& ref;
        bool  orig;
        ~ScopeGuard() { ref = orig; }
    } guard{ cfg.m_ZoneFillIterativeRefill, originalIterativeRefill };
 
    cfg.m_ZoneFillIterativeRefill = true;
    KI_TEST::LoadBoard( m_settingsManager, "issue24835/issue24835-min", m_board );
 
    BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
    bds.m_MinConn = pcbIUScale.mmToIU( 0.1016 );
    bds.m_DRCSeverities[ DRCE_CONNECTION_WIDTH ] = SEVERITY::RPT_SEVERITY_ERROR;
    bds.m_DRCEngine->InitEngine( wxFileName() );
 
    KI_TEST::FillZones( m_board.get() );
 
    const VECTOR2I bridgeCenter( pcbIUScale.mmToIU( 104.220616 ),
                                 pcbIUScale.mmToIU( 103.646866 ) );
 
    for( PCB_LAYER_ID layer : { In1_Cu, In4_Cu } )
    {
        double localCopperArea = 0.0;
 
        for( ZONE* zone : m_board->Zones() )
        {
            if( !zone->IsOnLayer( layer ) )
                continue;
 
            std::shared_ptr<SHAPE_POLY_SET> fill = zone->GetFilledPolysList( layer );
            SHAPE_POLY_SET                 local;
            int                            radius = pcbIUScale.mmToIU( 0.2 );
 
            local.NewOutline();
            local.Append( bridgeCenter + VECTOR2I( -radius, -radius ) );
            local.Append( bridgeCenter + VECTOR2I( radius, -radius ) );
            local.Append( bridgeCenter + VECTOR2I( radius, radius ) );
            local.Append( bridgeCenter + VECTOR2I( -radius, radius ) );
 
            if( fill )
                local.BooleanIntersection( *fill );
 
            localCopperArea = std::max( localCopperArea, std::abs( local.Area() ) );
        }
 
        double minimumLocalCopperArea = 0.05 * pcbIUScale.IU_PER_MM * pcbIUScale.IU_PER_MM;
 
        BOOST_CHECK_MESSAGE( localCopperArea > minimumLocalCopperArea,
                             wxString::Format( "Expected copper around the bridge on %s; the "
                                               "bridge must be widened, not removed.",
                                               LSET::Name( layer ) ) );
    }
 
    std::vector<DRC_ITEM> violations;
 
    bds.m_DRCEngine->SetViolationHandler(
            [&]( const std::shared_ptr<DRC_ITEM>& aItem, const VECTOR2I&, int,
                 const std::function<void( PCB_MARKER* )>& )
            {
                if( aItem->GetErrorCode() == DRCE_CONNECTION_WIDTH )
                    violations.push_back( *aItem );
            } );
 
    bds.m_DRCEngine->RunTests( EDA_UNITS::MM, true, false );
 
    BOOST_CHECK_MESSAGE( violations.empty(),
                         wxString::Format( "Iterative refill produced %zu connection_width "
                                           "violations; expected full-width bridges (issue 24835).",
                                           violations.size() ) );
}
 
 
// Issue 23790: the iterative refill's min-width cycle runs after the fill has been trimmed to the
// zone outline, so without the same-net apron a border shared with an abutting same-net zone looks
// like a free convex corner and gets rounded off.  Both fill modes must agree along such a border.
BOOST_FIXTURE_TEST_CASE( SameNetBorderIdenticalAcrossFillModes, ZONE_FILL_TEST_FIXTURE )
{
    ADVANCED_CFG& cfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
 
    struct ScopeGuard
    {
        bool& ref;
        bool  orig;
        ~ScopeGuard() { ref = orig; }
    } guard{ cfg.m_ZoneFillIterativeRefill, cfg.m_ZoneFillIterativeRefill };
 
    const PCB_LAYER_ID layer = F_Cu;
 
    auto fill =
            [&]( bool aIterativeRefill, std::unique_ptr<BOARD>& aBoard )
            {
                cfg.m_ZoneFillIterativeRefill = aIterativeRefill;
                KI_TEST::LoadBoard( m_settingsManager, "issue23790/issue23790", aBoard );
                KI_TEST::FillZones( aBoard.get() );
            };
 
    std::unique_ptr<BOARD> incremental;
    std::unique_ptr<BOARD> oneShot;
 
    fill( true, incremental );
    fill( false, oneShot );
 
    std::map<KIID, SHAPE_POLY_SET> incrementalFills;
 
    for( ZONE* zone : incremental->Zones() )
    {
        if( !zone->GetIsRuleArea() && zone->HasFilledPolysForLayer( layer ) )
            incrementalFills[zone->m_Uuid] = *zone->GetFilledPolysList( layer );
    }
 
    // The band in which a zone can be reached by an abutting same-net zone's copper.  Confining the
    // comparison to it excludes free outer corners, where the two modes legitimately round a little
    // differently.
    auto sameNetBorderBand =
            [&]( ZONE* aZone ) -> SHAPE_POLY_SET
            {
                SHAPE_POLY_SET self = aZone->Outline()->CloneDropTriangulation();
                self.ClearArcs();
                self.Inflate( aZone->GetMinThickness(), CORNER_STRATEGY::ROUND_ALL_CORNERS,
                              ARC_HIGH_DEF );
 
                SHAPE_POLY_SET band;
 
                for( ZONE* other : oneShot->Zones() )
                {
                    if( other == aZone || other->GetIsRuleArea()
                            || other->GetNetCode() != aZone->GetNetCode()
                            || !other->GetLayerSet().Contains( layer ) )
                    {
                        continue;
                    }
 
                    SHAPE_POLY_SET reach = other->Outline()->CloneDropTriangulation();
                    reach.ClearArcs();
                    reach.Inflate( other->GetMinThickness(), CORNER_STRATEGY::ROUND_ALL_CORNERS,
                                   ARC_HIGH_DEF );
                    reach.BooleanIntersection( self );
                    band.BooleanAdd( reach );
                }
 
                return band;
            };
 
    const double sqMM = pcbIUScale.IU_PER_MM * (double) pcbIUScale.IU_PER_MM;
    int          checkedZones = 0;
 
    for( ZONE* zone : oneShot->Zones() )
    {
        if( zone->GetIsRuleArea() || zone->GetNetCode() <= 0
                || !zone->HasFilledPolysForLayer( layer ) )
        {
            continue;
        }
 
        SHAPE_POLY_SET band = sameNetBorderBand( zone );
 
        if( band.OutlineCount() == 0 )
            continue;
 
        auto incrementalIt = incrementalFills.find( zone->m_Uuid );
 
        BOOST_REQUIRE_MESSAGE( incrementalIt != incrementalFills.end(),
                               wxString::Format( "Zone %s is missing from the incremental fill.",
                                                 zone->m_Uuid.AsString() ) );
 
        SHAPE_POLY_SET difference = *zone->GetFilledPolysList( layer );
        difference.BooleanXor( incrementalIt->second );
        difference.BooleanIntersection( band );
 
        const double differenceArea = difference.Area() / sqMM;
 
        BOOST_CHECK_MESSAGE( differenceArea < 0.01,
                wxString::Format( "Zone %s (priority %d) fills %.4f mm^2 differently along a "
                                  "shared same-net border depending on the fill mode; the two "
                                  "must agree there (issue 23790).",
                                  zone->m_Uuid.AsString(), zone->GetAssignedPriority(),
                                  differenceArea ) );
        checkedZones++;
    }
 
    BOOST_REQUIRE_MESSAGE( checkedZones >= 3,
                           wxString::Format( "Expected at least three zones sharing a same-net "
                                             "border, found %d.", checkedZones ) );
}
 

BOOST_FIXTURE_TEST_CASE( ThermalOverrideOnSolidZoneKeepsSpokes, ZONE_FILL_TEST_FIXTURE )
{
    KI_TEST::LoadBoard( m_settingsManager, "issue24865/issue24865", m_board );
 
    // Move the zone default away from thermal, so only the override asks for a relief.
    for( ZONE* zone : m_board->Zones() )
    {
        if( !zone->GetIsRuleArea() )
            zone->SetPadConnection( ZONE_CONNECTION::FULL );
    }
 
    PAD*         overriddenPad = nullptr;
    ZONE*        hostZone = nullptr;
    PCB_LAYER_ID hostLayer = UNDEFINED_LAYER;
 
    for( FOOTPRINT* footprint : m_board->Footprints() )
    {
        for( PAD* pad : footprint->Pads() )
        {
            for( ZONE* zone : m_board->Zones() )
            {
                if( zone->GetIsRuleArea() || zone->GetNetCode() != pad->GetNetCode() )
                    continue;
 
                for( PCB_LAYER_ID layer : zone->GetLayerSet() )
                {
                    if( !pad->IsOnLayer( layer ) || !pad->FlashLayer( layer ) )
                        continue;
 
                    if( !zone->Outline()->Contains( pad->GetPosition() ) )
                        continue;
 
                    overriddenPad = pad;
                    hostZone = zone;
                    hostLayer = layer;
                    break;
                }
 
                if( overriddenPad )
                    break;
            }
 
            if( overriddenPad )
                break;
        }
 
        if( overriddenPad )
            break;
    }
 
    BOOST_REQUIRE_MESSAGE( overriddenPad, "No same-net pad sits inside a zone on this board." );
 
    overriddenPad->SetLocalZoneConnection( ZONE_CONNECTION::THERMAL );
 
    KI_TEST::FillZones( m_board.get() );
 
    std::shared_ptr<SHAPE_POLY_SET> fill = hostZone->GetFilledPolysList( hostLayer );
 
    BOOST_REQUIRE_MESSAGE( fill && !fill->IsEmpty(),
                           wxString::Format( "Zone on %s did not fill.",
                                             m_board->GetLayerName( hostLayer ) ) );
 
    // A relief with spokes still overlaps the pad. A relief without them leaves a clear gap.
    std::shared_ptr<SHAPE> padShape = overriddenPad->GetEffectiveShape( hostLayer );
 
    BOOST_CHECK_MESSAGE( fill->Collide( padShape.get(), 0 ),
                         wxString::Format( "Pad %s on net %s overrides the zone to a thermal "
                                           "connection, but the fill no longer reaches it on %s.",
                                           overriddenPad->GetNumber(),
                                           overriddenPad->GetNetname(),
                                           m_board->GetLayerName( hostLayer ) ) );
}
 
 
// Issue 23790: a different-net knockout elsewhere in a zone must not notch the corner where it
// abuts a same-net zone along a shared edge
BOOST_FIXTURE_TEST_CASE( RegressionSameNetTouchingZonesCorner, ZONE_FILL_TEST_FIXTURE )
{
    ADVANCED_CFG& cfg = const_cast<ADVANCED_CFG&>( ADVANCED_CFG::GetCfg() );
 
    struct ScopeGuard
    {
        bool& ref;
        bool  orig;
        ~ScopeGuard() { ref = orig; }
    } guard{ cfg.m_ZoneFillIterativeRefill, cfg.m_ZoneFillIterativeRefill };
 
    cfg.m_ZoneFillIterativeRefill = true;
 
    KI_TEST::LoadBoard( m_settingsManager, "issue23790/touching_zones", m_board );
    KI_TEST::FillZones( m_board.get() );
 
    std::vector<ZONE*> rails;
 
    for( ZONE* zone : m_board->Zones() )
    {
        if( zone->GetNetname() == wxS( "gate_drv_rail" ) )
            rails.push_back( zone );
    }
 
    BOOST_REQUIRE_EQUAL( rails.size(), 2 );
 
    const PCB_LAYER_ID layer = F_Cu;
    const int          reach = rails[0]->GetMinThickness();
 
    // The band either side of the shared edge, within the combined outline
    SHAPE_POLY_SET nearA = *rails[0]->Outline();
    SHAPE_POLY_SET nearB = *rails[1]->Outline();
    nearA.Inflate( reach, CORNER_STRATEGY::ROUND_ALL_CORNERS, ARC_HIGH_DEF );
    nearB.Inflate( reach, CORNER_STRATEGY::ROUND_ALL_CORNERS, ARC_HIGH_DEF );
 
    SHAPE_POLY_SET seam = *rails[0]->Outline();
    seam.BooleanAdd( *rails[1]->Outline() );
    seam.BooleanIntersection( nearA );
    seam.BooleanIntersection( nearB );
 
    seam.BooleanSubtract( *rails[0]->GetFilledPolysList( layer ) );
    seam.BooleanSubtract( *rails[1]->GetFilledPolysList( layer ) );
 
    double uncovered = seam.Area() / ( pcbIUScale.IU_PER_MM * (double) pcbIUScale.IU_PER_MM );
 
    BOOST_CHECK_MESSAGE( uncovered < 0.01,
                         wxString::Format( "%.4f mm^2 unfilled at the shared edge", uncovered ) );
}