feat: add DRC check for vias too close to pads

index.ts

@@ -17,3 +17,4 @@ export {
 } from "./lib/run-all-checks"
 
 export { checkConnectorAccessibleOrientation } from "./lib/check-connector-accessible-orientation"
+export { checkViaToPadSpacing } from "./lib/check-via-to-pad-spacing"

lib/check-via-to-pad-spacing.ts

@@ -0,0 +1,177 @@
+import type {
+  AnyCircuitElement,
+  PcbVia,
+  PcbSmtPad,
+  PcbPlatedHole,
+  PcbViaClearanceError,
+} from "circuit-json"
+import { getReadableNameForElement } from "@tscircuit/circuit-json-util"
+import { DEFAULT_VIA_TO_PAD_MARGIN, EPSILON } from "lib/drc-defaults"
+
+type Pad = PcbSmtPad | PcbPlatedHole
+
+/**
+ * Get the effective radius of a pad for clearance calculations.
+ * For rectangular pads, returns the half-diagonal (conservative bounding circle).
+ * For circular pads/plated holes, returns the actual radius.
+ */
+function getPadRadius(pad: Pad): number {
+  if (pad.type === "pcb_smtpad") {
+    if (pad.shape === "circle") return pad.radius
+    if (
+      pad.shape === "rect" ||
+      pad.shape === "rotated_rect" ||
+      pad.shape === "pill" ||
+      pad.shape === "rotated_pill"
+    ) {
+      return Math.max(pad.width, pad.height) / 2
+    }
+    return 0
+  }
+  if (pad.type === "pcb_plated_hole") {
+    if (pad.shape === "circle") return pad.outer_diameter / 2
+    if (pad.shape === "oval" || pad.shape === "pill") {
+      return Math.max(pad.outer_width, pad.outer_height) / 2
+    }
+    if (pad.shape === "pill_hole_with_rect_pad") {
+      return Math.max(pad.rect_pad_width, pad.rect_pad_height) / 2
+    }
+    return 0
+  }
+  return 0
+}
+
+function getPadId(pad: Pad): string {
+  if (pad.type === "pcb_smtpad") return pad.pcb_smtpad_id
+  return pad.pcb_plated_hole_id
+}
+
+/**
+ * Compute the minimum distance between a via (circle) and a rectangular pad.
+ * Returns the edge-to-edge gap (negative if overlapping).
+ */
+function distanceViaToRectPad(
+  via: PcbVia,
+  pad: { x: number; y: number; width: number; height: number },
+): number {
+  const halfW = pad.width / 2
+  const halfH = pad.height / 2
+  // Nearest point on rectangle to via center
+  const nearestX = Math.max(pad.x - halfW, Math.min(via.x, pad.x + halfW))
+  const nearestY = Math.max(pad.y - halfH, Math.min(via.y, pad.y + halfH))
+  const dist = Math.hypot(via.x - nearestX, via.y - nearestY)
+  return dist - via.outer_diameter / 2
+}
+
+/**
+ * Compute the edge-to-edge gap between a via and a circular pad.
+ */
+function distanceViaToCirclePad(
+  via: PcbVia,
+  padX: number,
+  padY: number,
+  padRadius: number,
+): number {
+  const dist = Math.hypot(via.x - padX, via.y - padY)
+  return dist - via.outer_diameter / 2 - padRadius
+}
+
+/**
+ * Compute the edge-to-edge gap between a via and any pad type.
+ */
+function computeGap(via: PcbVia, pad: Pad): number {
+  if (pad.type === "pcb_smtpad") {
+    if (pad.shape === "circle") {
+      return distanceViaToCirclePad(via, pad.x, pad.y, pad.radius)
+    }
+    if (
+      pad.shape === "rect" ||
+      pad.shape === "rotated_rect" ||
+      pad.shape === "pill" ||
+      pad.shape === "rotated_pill"
+    ) {
+      return distanceViaToRectPad(via, {
+        x: pad.x,
+        y: pad.y,
+        width: pad.width,
+        height: pad.height,
+      })
+    }
+    // Fallback: use bounding circle
+    return distanceViaToCirclePad(via, pad.x, pad.y, getPadRadius(pad))
+  }
+  if (pad.type === "pcb_plated_hole") {
+    if (pad.shape === "circle") {
+      return distanceViaToCirclePad(via, pad.x, pad.y, pad.outer_diameter / 2)
+    }
+    if (pad.shape === "oval" || pad.shape === "pill") {
+      return distanceViaToRectPad(via, {
+        x: pad.x,
+        y: pad.y,
+        width: pad.outer_width,
+        height: pad.outer_height,
+      })
+    }
+    if (pad.shape === "pill_hole_with_rect_pad") {
+      return distanceViaToRectPad(via, {
+        x: pad.x,
+        y: pad.y,
+        width: pad.rect_pad_width,
+        height: pad.rect_pad_height,
+      })
+    }
+    return distanceViaToCirclePad(via, pad.x, pad.y, getPadRadius(pad))
+  }
+  return Number.POSITIVE_INFINITY
+}
+
+export function checkViaToPadSpacing(
+  circuitJson: AnyCircuitElement[],
+  {
+    minSpacing = DEFAULT_VIA_TO_PAD_MARGIN,
+  }: { minSpacing?: number } = {},
+): PcbViaClearanceError[] {
+  const vias = circuitJson.filter((el) => el.type === "pcb_via") as PcbVia[]
+  const pads: Pad[] = [
+    ...(circuitJson.filter((el) => el.type === "pcb_smtpad") as PcbSmtPad[]),
+    ...(circuitJson.filter(
+      (el) => el.type === "pcb_plated_hole",
+    ) as PcbPlatedHole[]),
+  ]
+
+  if (vias.length === 0 || pads.length === 0) return []
+
+  const errors: PcbViaClearanceError[] = []
+
+  for (const via of vias) {
+    for (const pad of pads) {
+      const gap = computeGap(via, pad)
+      if (gap + EPSILON >= minSpacing) continue
+
+      const padId = getPadId(pad)
+      const pairId = [via.pcb_via_id, padId].sort().join("_")
+
+      errors.push({
+        type: "pcb_via_clearance_error",
+        pcb_error_id: `via_pad_close_${pairId}`,
+        message: `Via ${getReadableNameForElement(
+          circuitJson,
+          via.pcb_via_id,
+        )} is too close to pad ${getReadableNameForElement(
+          circuitJson,
+          padId,
+        )} (gap: ${gap.toFixed(3)}mm, minimum: ${minSpacing}mm)`,
+        error_type: "pcb_via_clearance_error",
+        pcb_via_ids: [via.pcb_via_id],
+        minimum_clearance: minSpacing,
+        actual_clearance: gap,
+        pcb_center: {
+          x: (via.x + pad.x) / 2,
+          y: (via.y + pad.y) / 2,
+        },
+      })
+    }
+  }
+
+  return errors
+}

lib/drc-defaults.ts

@@ -5,5 +5,6 @@ export const DEFAULT_VIA_BOARD_MARGIN = 0.3
 
 export const DEFAULT_SAME_NET_VIA_MARGIN = 0.2
 export const DEFAULT_DIFFERENT_NET_VIA_MARGIN = 0.3
+export const DEFAULT_VIA_TO_PAD_MARGIN = 0.2
 
 export const EPSILON = 0.005

lib/run-all-checks.ts

@@ -8,6 +8,7 @@ import { checkPcbComponentOverlap } from "./check-pcb-components-overlap/checkPc
 import { checkConnectorAccessibleOrientation } from "./check-connector-accessible-orientation"
 import { checkPinMustBeConnected } from "./check-pin-must-be-connected"
 import { checkSameNetViaSpacing } from "./check-same-net-via-spacing"
+import { checkViaToPadSpacing } from "./check-via-to-pad-spacing"
 import { checkSourceTracesHavePcbTraces } from "./check-source-traces-have-pcb-traces"
 import { checkPcbTracesOutOfBoard } from "./check-trace-out-of-board/checkTraceOutOfBoard"
 import { checkTracesAreContiguous } from "./check-traces-are-contiguous/check-traces-are-contiguous"
@@ -32,6 +33,7 @@ export async function runAllRoutingChecks(circuitJson: AnyCircuitElement[]) {
     ...checkEachPcbTraceNonOverlapping(circuitJson),
     ...checkSameNetViaSpacing(circuitJson),
     ...checkDifferentNetViaSpacing(circuitJson),
+    ...checkViaToPadSpacing(circuitJson),
     // ...checkTracesAreContiguous(circuitJson),
     ...checkPcbTracesOutOfBoard(circuitJson),
   ]

tests/lib/check-via-to-pad-spacing/custom-min-spacing.test.ts

@@ -0,0 +1,31 @@
+import { expect, test } from "bun:test"
+import { checkViaToPadSpacing } from "lib/check-via-to-pad-spacing"
+import type { AnyCircuitElement } from "circuit-json"
+
+test("respects custom minSpacing parameter", () => {
+  const soup: AnyCircuitElement[] = [
+    {
+      type: "pcb_via",
+      pcb_via_id: "via1",
+      x: 0,
+      y: 0,
+      hole_diameter: 0.3,
+      outer_diameter: 0.6,
+      layers: ["top", "bottom"],
+    },
+    {
+      type: "pcb_smtpad",
+      pcb_smtpad_id: "pad1",
+      shape: "rect",
+      x: 1.0,
+      y: 0,
+      width: 0.4,
+      height: 0.3,
+      layer: "top",
+    },
+  ]
+  // Via edge at 0.3, pad left edge at 0.8 => gap = 0.5mm
+  // With default 0.2mm: no error. With 0.6mm: error
+  expect(checkViaToPadSpacing(soup)).toHaveLength(0)
+  expect(checkViaToPadSpacing(soup, { minSpacing: 0.6 })).toHaveLength(1)
+})

tests/lib/check-via-to-pad-spacing/no-pads.test.ts

@@ -0,0 +1,18 @@
+import { expect, test } from "bun:test"
+import { checkViaToPadSpacing } from "lib/check-via-to-pad-spacing"
+import type { AnyCircuitElement } from "circuit-json"
+
+test("returns empty array when no pads", () => {
+  const soup: AnyCircuitElement[] = [
+    {
+      type: "pcb_via",
+      pcb_via_id: "via1",
+      x: 0,
+      y: 0,
+      hole_diameter: 0.3,
+      outer_diameter: 0.6,
+      layers: ["top", "bottom"],
+    },
+  ]
+  expect(checkViaToPadSpacing(soup)).toHaveLength(0)
+})

tests/lib/check-via-to-pad-spacing/no-vias.test.ts

@@ -0,0 +1,19 @@
+import { expect, test } from "bun:test"
+import { checkViaToPadSpacing } from "lib/check-via-to-pad-spacing"
+import type { AnyCircuitElement } from "circuit-json"
+
+test("returns empty array when no vias", () => {
+  const soup: AnyCircuitElement[] = [
+    {
+      type: "pcb_smtpad",
+      pcb_smtpad_id: "pad1",
+      shape: "rect",
+      x: 0,
+      y: 0,
+      width: 0.4,
+      height: 0.3,
+      layer: "top",
+    },
+  ]
+  expect(checkViaToPadSpacing(soup)).toHaveLength(0)
+})

tests/lib/check-via-to-pad-spacing/via-close-to-circle-pad.test.ts

@@ -0,0 +1,30 @@
+import { expect, test } from "bun:test"
+import { checkViaToPadSpacing } from "lib/check-via-to-pad-spacing"
+import type { AnyCircuitElement } from "circuit-json"
+
+test("no error when via gap to circular SMT pad equals minSpacing", () => {
+  const soup: AnyCircuitElement[] = [
+    {
+      type: "pcb_via",
+      pcb_via_id: "via1",
+      x: 0,
+      y: 0,
+      hole_diameter: 0.3,
+      outer_diameter: 0.6,
+      layers: ["top", "bottom"],
+    },
+    {
+      type: "pcb_smtpad",
+      pcb_smtpad_id: "pad1",
+      shape: "circle",
+      x: 0.7,
+      y: 0,
+      radius: 0.2,
+      layer: "top",
+    },
+  ]
+  // center-to-center = 0.7, via radius = 0.3, pad radius = 0.2 => gap = 0.2mm
+  // gap + EPSILON (0.005) >= 0.2mm minSpacing => no error
+  const errors = checkViaToPadSpacing(soup)
+  expect(errors).toHaveLength(0)
+})

tests/lib/check-via-to-pad-spacing/via-close-to-plated-hole.test.ts

@@ -0,0 +1,33 @@
+import { expect, test } from "bun:test"
+import { checkViaToPadSpacing } from "lib/check-via-to-pad-spacing"
+import type { AnyCircuitElement } from "circuit-json"
+
+test("returns error when via is too close to a plated hole", () => {
+  const soup: AnyCircuitElement[] = [
+    {
+      type: "pcb_via",
+      pcb_via_id: "via1",
+      x: 0,
+      y: 0,
+      hole_diameter: 0.3,
+      outer_diameter: 0.6,
+      layers: ["top", "bottom"],
+    },
+    {
+      type: "pcb_plated_hole",
+      pcb_plated_hole_id: "hole1",
+      shape: "circle",
+      x: 0.6,
+      y: 0,
+      hole_diameter: 0.3,
+      outer_diameter: 0.5,
+      layers: ["top", "bottom"],
+      pcb_component_id: "comp1",
+      pcb_port_id: "port1",
+    },
+  ]
+  // center-to-center = 0.6, via radius = 0.3, hole radius = 0.25 => gap = 0.05mm < 0.2mm
+  const errors = checkViaToPadSpacing(soup)
+  expect(errors).toHaveLength(1)
+  expect(errors[0].message).toContain("too close to pad")
+})

tests/lib/check-via-to-pad-spacing/via-far-from-pad.test.ts

@@ -0,0 +1,29 @@
+import { expect, test } from "bun:test"
+import { checkViaToPadSpacing } from "lib/check-via-to-pad-spacing"
+import type { AnyCircuitElement } from "circuit-json"
+
+test("no error when via is far from pad", () => {
+  const soup: AnyCircuitElement[] = [
+    {
+      type: "pcb_via",
+      pcb_via_id: "via1",
+      x: 0,
+      y: 0,
+      hole_diameter: 0.3,
+      outer_diameter: 0.6,
+      layers: ["top", "bottom"],
+    },
+    {
+      type: "pcb_smtpad",
+      pcb_smtpad_id: "pad1",
+      shape: "rect",
+      x: 2,
+      y: 0,
+      width: 0.4,
+      height: 0.3,
+      layer: "top",
+    },
+  ]
+  const errors = checkViaToPadSpacing(soup)
+  expect(errors).toHaveLength(0)
+})