Use shared board surface offsets for copper features

package.json

@@ -52,7 +52,7 @@
     "@tscircuit/checks": "^0.0.85",
     "@tscircuit/math-utils": "^0.0.27",
     "@tscircuit/capacity-autorouter": "^0.0.131",
-    "calculate-packing": "^0.0.48",
+    "calculate-packing": "^0.0.50",
     "@types/jsdom": "^21.1.7",
     "@types/react": "19",
     "@types/react-dom": "19",

src/BoardGeomBuilder.ts

@@ -34,6 +34,7 @@ import {
   colors,
   boardMaterialColors,
   tracesMaterialColors,
+  BOARD_SURFACE_OFFSET,
 } from "./geoms/constants"
 import { extrudeLinear } from "@jscad/modeling/src/operations/extrusions"
 import { expand } from "@jscad/modeling/src/operations/expansions"
@@ -378,7 +379,9 @@ export class BoardGeomBuilder {
 
   private processCopperPour(pour: PcbCopperPour) {
     const layerSign = pour.layer === "bottom" ? -1 : 1
-    const zPos = (layerSign * this.ctx.pcbThickness) / 2 + layerSign * M
+    const zPos =
+      (layerSign * this.ctx.pcbThickness) / 2 +
+      layerSign * BOARD_SURFACE_OFFSET.copper
 
     let pourGeom: Geom3 | null = null
 
@@ -655,7 +658,9 @@ export class BoardGeomBuilder {
 
   private processPad(pad: PcbSmtPad) {
     const layerSign = pad.layer === "bottom" ? -1 : 1
-    const zPos = (layerSign * this.ctx.pcbThickness) / 2 + layerSign * M * 2 // Slightly offset from board surface
+    const zPos =
+      (layerSign * this.ctx.pcbThickness) / 2 +
+      layerSign * BOARD_SURFACE_OFFSET.copper // Slightly offset from board surface
 
     const rectBorderRadius = extractRectBorderRadius(pad)
 
@@ -716,7 +721,9 @@ export class BoardGeomBuilder {
     const finishSegment = () => {
       if (currentSegmentPoints.length >= 2 && currentLayer) {
         const layerSign = currentLayer === "bottom" ? -1 : 1
-        const zPos = (layerSign * this.ctx.pcbThickness) / 2 + layerSign * M
+        const zCenter =
+          (layerSign * this.ctx.pcbThickness) / 2 +
+          layerSign * BOARD_SURFACE_OFFSET.traces
 
         const linePath = line(currentSegmentPoints)
         // Use the width of the starting point of the segment for consistency
@@ -725,7 +732,7 @@ export class BoardGeomBuilder {
           linePath,
         )
         let traceGeom = translate(
-          [0, 0, zPos],
+          [0, 0, zCenter - M / 2],
           extrudeLinear({ height: M }, expandedPath),
         )
 
@@ -740,7 +747,7 @@ export class BoardGeomBuilder {
         )
         if (startHole) {
           const cuttingCylinder = cylinder({
-            center: [startPointCoords[0], startPointCoords[1], zPos + M / 2],
+            center: [startPointCoords[0], startPointCoords[1], zCenter],
             radius: startHole.diameter / 2 + M,
             height: M,
           })
@@ -750,7 +757,7 @@ export class BoardGeomBuilder {
         const endHole = this.getHoleToCut(endPointCoords[0], endPointCoords[1])
         if (endHole) {
           const cuttingCylinder = cylinder({
-            center: [endPointCoords[0], endPointCoords[1], zPos + M / 2],
+            center: [endPointCoords[0], endPointCoords[1], zCenter],
             radius: endHole.diameter / 2 + M,
             height: M,
           })

src/geoms/constants.ts

@@ -3,6 +3,11 @@ import type { PcbBoard } from "circuit-json"
 
 export const M = 0.01
 
+export const BOARD_SURFACE_OFFSET = {
+  traces: 0.001,
+  copper: 0.002,
+} as const
+
 export const colors = {
   copper: [0.9, 0.6, 0.2],
   fr4Green: [0.04, 0.16, 0.08],

src/geoms/plated-hole.ts

@@ -11,7 +11,7 @@ import {
   subtract,
   union,
 } from "@jscad/modeling/src/operations/booleans"
-import { M, colors } from "./constants"
+import { BOARD_SURFACE_OFFSET, M, colors } from "./constants"
 import type { GeomContext } from "../GeomContext"
 import { extrudeLinear } from "@jscad/modeling/src/operations/extrusions"
 import { translate } from "@jscad/modeling/src/operations/transforms"
@@ -67,10 +67,13 @@ export const platedHole = (
   const { clipGeom } = options
   if (!(plated_hole as PCBPlatedHole).shape) plated_hole.shape = "circle"
   const throughDrillHeight = ctx.pcbThickness + 2 * platedHoleLipHeight + 4 * M
+  const topSurfaceZ = ctx.pcbThickness / 2 + BOARD_SURFACE_OFFSET.copper
+  const bottomSurfaceZ = -ctx.pcbThickness / 2 - BOARD_SURFACE_OFFSET.copper
+  const copperSpan = topSurfaceZ - bottomSurfaceZ
   if (plated_hole.shape === "circle") {
     const outerDiameter =
       plated_hole.outer_diameter ?? Math.max(plated_hole.hole_diameter, 0)
-    const copperHeight = ctx.pcbThickness + 2 * platedHoleLipHeight
+    const copperHeight = copperSpan
     const copperBody = cylinder({
       center: [plated_hole.x, plated_hole.y, 0],
       radius: outerDiameter / 2,
@@ -104,7 +107,7 @@ export const platedHole = (
           center: [
             plated_hole.x,
             plated_hole.y,
-            ctx.pcbThickness / 2 + platedHoleLipHeight / 2 + M - 0.05, // Adjusted for thickness
+            topSurfaceZ - platedHoleLipHeight / 2,
           ],
           borderRadius: rectBorderRadius,
         }),
@@ -116,26 +119,24 @@ export const platedHole = (
           center: [
             plated_hole.x,
             plated_hole.y,
-            -ctx.pcbThickness / 2 - platedHoleLipHeight / 2 - M + 0.05, // Adjusted for thickness
+            bottomSurfaceZ + platedHoleLipHeight / 2,
           ],
           borderRadius: rectBorderRadius,
         }),
         // Main copper fill between pads with rounded corners
         (() => {
-          const height =
-            ctx.pcbThickness - platedHoleLipHeight * 2 - M * 2 + 0.1
+          const height = Math.max(copperSpan - platedHoleLipHeight * 2, M)
+          const topPadBottom = topSurfaceZ - platedHoleLipHeight
+          const bottomPadTop = bottomSurfaceZ + platedHoleLipHeight
+          const centerZ = (topPadBottom + bottomPadTop) / 2
           const rect2d = roundedRectangle({
             size: [padWidth, padHeight],
             roundRadius: rectBorderRadius || 0,
             segments: RECT_PAD_SEGMENTS,
           })
           const extruded = extrudeLinear({ height }, rect2d)
           return translate(
-            [
-              plated_hole.x,
-              plated_hole.y,
-              -height / 2, // Center vertically
-            ],
+            [plated_hole.x, plated_hole.y, centerZ - height / 2],
             extruded,
           )
         })(),
@@ -147,7 +148,7 @@ export const platedHole = (
             0,
           ],
           radius: plated_hole.hole_diameter / 2,
-          height: ctx.pcbThickness,
+          height: copperSpan,
         }),
       ),
       clipGeom,
@@ -171,7 +172,7 @@ export const platedHole = (
         0,
       ],
       radius: plated_hole.hole_diameter / 2,
-      height: ctx.pcbThickness,
+      height: copperSpan,
     })
 
     // Create the final copper solid with the offset barrel and hole
@@ -214,7 +215,7 @@ export const platedHole = (
     const outerRadius = outerPillHeight / 2
     const rectLength = Math.abs(holeWidth - holeHeight)
     const outerRectLength = Math.abs(outerPillWidth - outerPillHeight)
-    const copperHeight = ctx.pcbThickness + 2 * (platedHoleLipHeight + M)
+    const copperHeight = copperSpan
 
     const createPillSection = (
       width: number,
@@ -319,12 +320,12 @@ export const platedHole = (
           ? [
               holeHeight + 2 * barrelMargin,
               rectLength + 2 * barrelMargin,
-              ctx.pcbThickness + 0.02,
+              copperSpan,
             ]
           : [
               rectLength + 2 * barrelMargin,
               holeHeight + 2 * barrelMargin,
-              ctx.pcbThickness,
+              copperSpan,
             ],
       }),
       cylinder({
@@ -340,7 +341,7 @@ export const platedHole = (
               0,
             ],
         radius: holeRadius + barrelMargin,
-        height: ctx.pcbThickness + 0.02,
+        height: copperSpan,
       }),
       cylinder({
         center: shouldRotate
@@ -355,7 +356,7 @@ export const platedHole = (
               0,
             ],
         radius: holeRadius + barrelMargin,
-        height: ctx.pcbThickness + 0.02,
+        height: copperSpan,
       }),
     )
 
@@ -407,7 +408,7 @@ export const platedHole = (
       center: [
         plated_hole.x,
         plated_hole.y,
-        ctx.pcbThickness / 2 + platedHoleLipHeight / 2 + M - 0.05,
+        topSurfaceZ - platedHoleLipHeight / 2,
       ],
       borderRadius: rectBorderRadius,
     })
@@ -419,20 +420,26 @@ export const platedHole = (
       center: [
         plated_hole.x,
         plated_hole.y,
-        -ctx.pcbThickness / 2 - platedHoleLipHeight / 2 - M + 0.05,
+        bottomSurfaceZ + platedHoleLipHeight / 2,
       ],
       borderRadius: rectBorderRadius,
     })
 
     const copperFill = (() => {
-      const height = ctx.pcbThickness - platedHoleLipHeight * 2 - M * 2 + 0.1
+      const height = Math.max(copperSpan - platedHoleLipHeight * 2, M)
+      const topPadBottom = topSurfaceZ - platedHoleLipHeight
+      const bottomPadTop = bottomSurfaceZ + platedHoleLipHeight
+      const centerZ = (topPadBottom + bottomPadTop) / 2
       const rect2d = roundedRectangle({
         size: [padWidth, padHeight],
         roundRadius: rectBorderRadius || 0,
         segments: RECT_PAD_SEGMENTS,
       })
       const extruded = extrudeLinear({ height }, rect2d)
-      return translate([plated_hole.x, plated_hole.y, -height / 2], extruded)
+      return translate(
+        [plated_hole.x, plated_hole.y, centerZ - height / 2],
+        extruded,
+      )
     })()
 
     // --- Cut pads with the hole ---

src/utils/manifold/process-plated-holes.ts

@@ -11,6 +11,7 @@ import {
   SMOOTH_CIRCLE_SEGMENTS,
   DEFAULT_SMT_PAD_THICKNESS,
   M,
+  BOARD_SURFACE_OFFSET,
 } from "../../geoms/constants"
 import { extractRectBorderRadius } from "../rect-border-radius"
 
@@ -221,7 +222,11 @@ export function processPlatedHolesForManifold(
         Manifold,
         width: padWidth,
         height: padHeight,
-        thickness: pcbThickness - 2 * padThickness + 0.1, // Fill between pads
+        thickness:
+          pcbThickness -
+          2 * padThickness -
+          2 * BOARD_SURFACE_OFFSET.copper +
+          0.1, // Fill between pads
         borderRadius: rectBorderRadius,
       })
       manifoldInstancesForCleanup.push(mainFill)
@@ -233,15 +238,23 @@ export function processPlatedHolesForManifold(
         height: padHeight,
         thickness: padThickness,
         borderRadius: rectBorderRadius,
-      }).translate([0, 0, pcbThickness / 2 - padThickness / 2 + 0.05])
+      }).translate([
+        0,
+        0,
+        pcbThickness / 2 - padThickness / 2 + BOARD_SURFACE_OFFSET.copper,
+      ])
 
       const bottomPad = createRoundedRectPrism({
         Manifold,
         width: padWidth,
         height: padHeight,
         thickness: padThickness,
         borderRadius: rectBorderRadius,
-      }).translate([0, 0, -pcbThickness / 2 + padThickness / 2 - 0.05])
+      }).translate([
+        0,
+        0,
+        -pcbThickness / 2 + padThickness / 2 - BOARD_SURFACE_OFFSET.copper,
+      ])
       manifoldInstancesForCleanup.push(topPad, bottomPad)
 
       // Create the plated barrel at the offset position
@@ -325,7 +338,11 @@ export function processPlatedHolesForManifold(
         Manifold,
         width: padWidth!,
         height: padHeight!,
-        thickness: pcbThickness - 2 * padThickness + 0.1, // Fill between pads
+        thickness:
+          pcbThickness -
+          2 * padThickness -
+          2 * BOARD_SURFACE_OFFSET.copper +
+          0.1, // Fill between pads
         borderRadius: rectBorderRadius,
       })
       manifoldInstancesForCleanup.push(mainFill)
@@ -337,15 +354,23 @@ export function processPlatedHolesForManifold(
         height: padHeight!,
         thickness: padThickness,
         borderRadius: rectBorderRadius,
-      }).translate([0, 0, pcbThickness / 2 - padThickness / 2 + 0.05])
+      }).translate([
+        0,
+        0,
+        pcbThickness / 2 - padThickness / 2 + BOARD_SURFACE_OFFSET.copper,
+      ])
 
       const bottomPad = createRoundedRectPrism({
         Manifold,
         width: padWidth!,
         height: padHeight!,
         thickness: padThickness,
         borderRadius: rectBorderRadius,
-      }).translate([0, 0, -pcbThickness / 2 + padThickness / 2 - 0.05])
+      }).translate([
+        0,
+        0,
+        -pcbThickness / 2 + padThickness / 2 - BOARD_SURFACE_OFFSET.copper,
+      ])
       manifoldInstancesForCleanup.push(topPad, bottomPad)
 
       // Create the plated barrel at the offset position