board-make.yml

name: Board make

# End-to-end: Freerouting → SES → PCB → KiCad zone refill → DRC gate.
# Fast PR CI still uses the pinned manufacturing board in build.yml.
# This workflow runs on demand, nightly, and when route inputs / stack change.
# To refresh the manufacturing pin after a green run: download board-make-filled
# and run `bun run board:make -- --skip-route --pin` locally (or copy artifacts).

on:
  workflow_dispatch:
  schedule:
    - cron: "0 6 * * *"
  pull_request:
    paths:
      - "ci/artifacts/v3-for-route.kicad_pcb"
      - "ci/artifacts/v3-for-route.dsn"
      - "ci/artifacts/v3-for-route.kicad_pro"
      - "ci/artifacts/fp-lib-table"
      - "pcbkit/profiles/lightbar-dock.toml"
      - "pcbkit/crates/pcbkit-route/**"
      - "pcbkit/crates/pcbkit-cli/**"
      - "scripts/board-make.mjs"
      - "scripts/route-board-pcbkit.mjs"
      - "scripts/ensure-java.mjs"
      - "scripts/kicad-env.mjs"
      - ".github/workflows/board-make.yml"
  push:
    branches: [master]
    paths:
      - "ci/artifacts/v3-for-route.kicad_pcb"
      - "ci/artifacts/v3-for-route.dsn"
      - "ci/artifacts/v3-for-route.kicad_pro"
      - "ci/artifacts/fp-lib-table"
      - "pcbkit/profiles/lightbar-dock.toml"
      - "pcbkit/crates/pcbkit-route/**"
      - "pcbkit/crates/pcbkit-cli/**"
      - "scripts/board-make.mjs"
      - "scripts/route-board-pcbkit.mjs"
      - "scripts/ensure-java.mjs"
      - "scripts/kicad-env.mjs"
      - ".github/workflows/board-make.yml"

concurrency:
  group: board-make-${{ github.ref }}
  cancel-in-progress: true

env:
  FREEROUTING_VERSION: "2.2.4"
  FREEROUTING_JAR: third_party/freerouting/freerouting-2.2.4.jar

jobs:
  route:
    runs-on: ubuntu-latest
    steps:
      - uses: actions/checkout@v4
        with:
          submodules: recursive

      - uses: oven-sh/setup-bun@v2
        with:
          bun-version: 1.3.14

      - uses: dtolnay/rust-toolchain@stable

      - uses: actions/setup-java@v4
        with:
          distribution: temurin
          # Freerouting 2.2.4 is classfile 69 → Java 25+.
          java-version: "25"

      - name: Cache cargo
        uses: actions/cache@v4
        with:
          path: |
            ~/.cargo/registry
            ~/.cargo/git
            pcbkit/target
          key: pcbkit-boardmake-${{ runner.os }}-${{ hashFiles('pcbkit/Cargo.lock', 'pcbkit/**/Cargo.toml') }}

      - name: Fetch Freerouting JAR
        run: |
          mkdir -p third_party/freerouting
          if [[ ! -f "$FREEROUTING_JAR" ]]; then
            curl -fsSL -o "$FREEROUTING_JAR" \
              "https://github.com/freerouting/freerouting/releases/download/v${FREEROUTING_VERSION}/freerouting-${FREEROUTING_VERSION}.jar"
          fi
          ls -la "$FREEROUTING_JAR"

      - name: Symlink Java for pcbkit profile
        run: |
          mkdir -p third_party/java/bin
          ln -sfn "$JAVA_HOME/bin/java" third_party/java/bin/java
          third_party/java/bin/java -version

      - run: bun install --frozen-lockfile

      - name: Build pcbkit
        run: cargo build --release --manifest-path pcbkit/Cargo.toml -p pcbkit-cli

      - name: DSN freshness (placement vs Specctra)
        run: bun run dsn:check

      - name: Route board (Freerouting + USB repairs)
        run: bun run board:make -- --route-only

      - name: Upload routed (unfilled) PCB
        uses: actions/upload-artifact@v4
        with:
          name: board-make-routed
          path: |
            generated/kicad/v3-board-make.kicad_pcb
            generated/kicad/v3-board-make.kicad_pro

  kicad-fill-drc:
    needs: route
    runs-on: ubuntu-latest
    container:
      image: kicad/kicad:10.0
      options: --user root
    steps:
      - uses: actions/checkout@v4

      - name: Download routed PCB
        uses: actions/download-artifact@v4
        with:
          name: board-make-routed
          path: board-make-routed

      - name: Stage board + fp-lib-table
        run: |
          mkdir -p generated/kicad
          if [[ -f board-make-routed/generated/kicad/v3-board-make.kicad_pcb ]]; then
            cp board-make-routed/generated/kicad/* generated/kicad/
          elif [[ -f board-make-routed/kicad/v3-board-make.kicad_pcb ]]; then
            cp board-make-routed/kicad/* generated/kicad/
          else
            cp board-make-routed/v3-board-make.kicad_pcb generated/kicad/
            cp board-make-routed/v3-board-make.kicad_pro generated/kicad/
          fi
          cp -f ci/artifacts/fp-lib-table generated/kicad/fp-lib-table
          ls -la generated/kicad

      - name: Zone refill + DRC
        working-directory: generated/kicad
        run: |
          mkdir -p ../reports
          # Run beside .kicad_pro + fp-lib-table so project rules / tscircuit lib load.
          kicad-cli pcb drc --format json --severity-error --severity-warning \
            --refill-zones --save-board \
            -o ../reports/v3-board-make-drc.json \
            v3-board-make.kicad_pcb

      - name: Upload filled PCB + DRC JSON
        uses: actions/upload-artifact@v4
        with:
          name: board-make-filled
          path: |
            generated/kicad/v3-board-make.kicad_pcb
            generated/kicad/v3-board-make.kicad_pro
            generated/reports/v3-board-make-drc.json

  gate:
    needs: [kicad-fill-drc]
    runs-on: ubuntu-latest
    steps:
      - uses: actions/checkout@v4
        with:
          submodules: recursive

      - uses: oven-sh/setup-bun@v2
        with:
          bun-version: 1.3.14

      - uses: dtolnay/rust-toolchain@stable

      - name: Cache cargo
        uses: actions/cache@v4
        with:
          path: |
            ~/.cargo/registry
            ~/.cargo/git
            pcbkit/target
          key: pcbkit-boardmake-${{ runner.os }}-${{ hashFiles('pcbkit/Cargo.lock', 'pcbkit/**/Cargo.toml') }}

      - name: Build pcbkit
        run: cargo build --release --manifest-path pcbkit/Cargo.toml -p pcbkit-cli

      - name: Download filled board + DRC
        uses: actions/download-artifact@v4
        with:
          name: board-make-filled
          path: board-make-out

      - name: Normalize artifact layout
        run: |
          # upload-artifact may strip the common `generated/` prefix.
          mkdir -p generated/kicad generated/reports
          if [[ -f board-make-out/generated/kicad/v3-board-make.kicad_pcb ]]; then
            cp board-make-out/generated/kicad/* generated/kicad/
            cp board-make-out/generated/reports/* generated/reports/
          else
            cp board-make-out/kicad/* generated/kicad/
            cp board-make-out/reports/* generated/reports/
          fi
          ls -la generated/kicad generated/reports

      - name: DRC gate (0 unconnected, 0 copper/silk errors)
        run: |
          ./pcbkit/target/release/pcbkit drc-gate \
            -j generated/reports/v3-board-make-drc.json \
            --max-unconnected 0 \
            --max-fatal-errors 0 \
            --max-type silk_edge_clearance=0 \
            --max-type lib_footprint_issues=0 \
            --max-type silk_over_copper=0

      - run: bun install --frozen-lockfile

      - name: Build circuit-json for assure
        run: bun run build:circuit

      - name: Assure against freshly made board
        run: |
          ./pcbkit/target/release/pcbkit assure \
            -i build/lightbar-dock.circuit.json \
            --fab pcbkit/profiles/fab-jlcpcb-2layer.toml \
            --golden circuit/assurance/golden-footprints.json \
            --pcb generated/kicad/v3-board-make.kicad_pcb \
            --skip-manifest \
            --bringup circuit/assurance/bringup.toml