Refactor PCB export script to combine individual layer PDFs into a single output file (#16)

* Refactor PCB export script to combine individual layer PDFs into a single output file
* chore: update kicaddev Docker image to version 1.6.0 across all configurations

Author: the78mole

.devcontainer/README.md

@@ -6,7 +6,7 @@ This DevContainer provides a complete hardware development environment for the K
 
 1. Open this folder in VS Code
 2. Click "Reopen in Container" when prompted
-3. Container starts in ~30 seconds using `ghcr.io/the78mole/kicaddev:1.5.0`
+3. Container starts in ~30 seconds using `ghcr.io/the78mole/kicaddev:1.6.0`
 
 ## ✨ Features Included
 

.devcontainer/STATUS.md

@@ -6,7 +6,7 @@ The DevContainer environment for the KM217 hardware project is fully configured
 
 ### 🚀 What has been implemented:
 
-1. **Pre-built Docker Image**: Using `ghcr.io/the78mole/kicaddev:1.5.0`
+1. **Pre-built Docker Image**: Using `ghcr.io/the78mole/kicaddev:1.6.0`
 2. **Performance**: Startup time of ~30 seconds
 3. **Simplified Structure**: Only essential configuration files
 4. **Optimized Documentation**: Focus on essential features

.devcontainer/devcontainer.json

@@ -1,6 +1,6 @@
 {
 	"name": "KM217 Hardware Development Environment",
-	"image": "ghcr.io/the78mole/kicaddev:1.5.0",
+	"image": "ghcr.io/the78mole/kicaddev:1.6.0",
 	"features": {
 		"ghcr.io/devcontainers/features/common-utils:2": {
 			"installZsh": true,

.devcontainer/test-devcontainer.sh

@@ -28,7 +28,7 @@ fi
 echo ""
 echo "🐳 Container Quick Test:"
 echo "Testing if container can start and run basic commands..."
-docker run --rm ghcr.io/the78mole/kicaddev:1.5.0 bash -c "
+docker run --rm ghcr.io/the78mole/kicaddev:1.6.0 bash -c "
 echo 'Container startup: ✅'
 echo 'KiCad version:' \$(kicad-cli version 2>/dev/null | head -1 || echo 'KiCad CLI not found')
 echo 'Python version:' \$(python3 --version)

.github/workflows/pr-check.yml

@@ -52,7 +52,7 @@ jobs:
     runs-on: ubuntu-latest
     needs: load-config
     container:
-      image: ghcr.io/the78mole/kicaddev:1.5.0
+      image: ghcr.io/the78mole/kicaddev:1.6.0
 
     strategy:
       matrix:
@@ -199,7 +199,7 @@ jobs:
     name: 📚 Documentation Build
     runs-on: ubuntu-latest
     container:
-      image: ghcr.io/the78mole/kicaddev:1.5.0
+      image: ghcr.io/the78mole/kicaddev:1.6.0
 
     steps:
     - name: 📥 Checkout Repository

.github/workflows/release.yml

@@ -75,7 +75,7 @@ jobs:
     runs-on: ubuntu-latest
     needs: [version, load-config]
     container:
-      image: ghcr.io/the78mole/kicaddev:1.5.0
+      image: ghcr.io/the78mole/kicaddev:1.6.0
 
     strategy:
       matrix: 
@@ -176,7 +176,7 @@ jobs:
     runs-on: ubuntu-latest
     needs: [version]
     container:
-      image: ghcr.io/the78mole/kicaddev:1.5.0
+      image: ghcr.io/the78mole/kicaddev:1.6.0
 
     steps:
     - name: 📥 Checkout Repository

.github/workflows/scripts/export-pcb-pdf.sh

@@ -23,28 +23,69 @@ while [[ $# -gt 0 ]]; do
     esac
 done
 
-echo "📄 Exporting PCB layout to PDF for ${PROJECT_DESCRIPTION}..."
+echo "📄 Exporting PCB layout to combined PDF for ${PROJECT_DESCRIPTION}..."
 cd "${PROJECT_PATH}"
 
-# Export PCB top layer
+# Create temporary directory for individual pages
+TEMP_DIR="Export/PDF/temp"
+mkdir -p "${TEMP_DIR}"
+
+# Export individual layer pages
+echo "📄 Exporting User.Drawings + Edge.Cuts..."
 kicad-cli pcb export pdf \
-  --output "Export/PDF/${PROJECT_NAME}-PCB-Top.pdf" \
+  --output "${TEMP_DIR}/01-user-drawings.pdf" \
+  --layers "User.Drawings,Edge.Cuts" \
+  ${PROJECT_NAME}.kicad_pcb
+
+echo "📄 Exporting F.Cu + Edge.Cuts..."
+kicad-cli pcb export pdf \
+  --output "${TEMP_DIR}/02-front-copper.pdf" \
+  --layers "F.Cu,Edge.Cuts" \
+  ${PROJECT_NAME}.kicad_pcb
+
+echo "📄 Exporting B.Cu + Edge.Cuts (mirrored)..."
+kicad-cli pcb export pdf \
+  --output "${TEMP_DIR}/03-back-copper.pdf" \
+  --layers "B.Cu,Edge.Cuts" \
+  --mirror \
+  ${PROJECT_NAME}.kicad_pcb
+
+echo "📄 Exporting F.Cu + F.Silkscreen + F.Mask + Edge.Cuts..."
+kicad-cli pcb export pdf \
+  --output "${TEMP_DIR}/04-front-assembly.pdf" \
   --layers "F.Cu,F.Silkscreen,F.Mask,Edge.Cuts" \
   ${PROJECT_NAME}.kicad_pcb
-  
-# Export PCB bottom layer  
+
+echo "📄 Exporting B.Cu + B.Silkscreen + B.Mask + Edge.Cuts (mirrored)..."
 kicad-cli pcb export pdf \
-  --output "Export/PDF/${PROJECT_NAME}-PCB-Bottom.pdf" \
+  --output "${TEMP_DIR}/05-back-assembly.pdf" \
   --layers "B.Cu,B.Silkscreen,B.Mask,Edge.Cuts" \
+  --mirror \
   ${PROJECT_NAME}.kicad_pcb
+
+# Combine all PDFs into one using pdftk
+echo "📄 Combining all layers into single PDF using pdftk..."
+COMBINED_PDF="Export/PDF/${PROJECT_NAME}-PCB-Complete.pdf"
+
+pdftk "${TEMP_DIR}"/01-user-drawings.pdf \
+      "${TEMP_DIR}"/02-front-copper.pdf \
+      "${TEMP_DIR}"/03-back-copper.pdf \
+      "${TEMP_DIR}"/04-front-assembly.pdf \
+      "${TEMP_DIR}"/05-back-assembly.pdf \
+      cat output "${COMBINED_PDF}"
+
+# Clean up temporary files
+rm -rf "${TEMP_DIR}"
+
+# Verify export
+if [ -f "${COMBINED_PDF}" ]; then
+  echo "✅ ${PROJECT_NAME}-PCB-Complete.pdf exported successfully (5 pages)"
+  ls -lh "${COMBINED_PDF}"
 
-# Verify exports
-for pdf in "Export/PDF/${PROJECT_NAME}-PCB-Top.pdf" "Export/PDF/${PROJECT_NAME}-PCB-Bottom.pdf"; do
-  if [ -f "$pdf" ]; then
-    echo "✅ $(basename $pdf) exported successfully"
-    ls -lh "$pdf"
-  else
-    echo "❌ Error: $(basename $pdf) export failed!"
-    exit 1
-  fi
-done
+  # Show page count using pdftk
+  PAGE_COUNT=$(pdftk "${COMBINED_PDF}" dump_data 2>/dev/null | grep NumberOfPages | awk '{print $2}' || echo "5")
+  echo "📄 PDF contains ${PAGE_COUNT} pages"
+else
+  echo "❌ Error: Combined PCB PDF export failed!"
+  exit 1
+fi

.github/workflows/scripts/generate-production-summary-pr.sh

@@ -50,8 +50,7 @@ $(ls -1 Export/Gerbers/ | sed 's/^/- /')
 $(ls -1 Export/Drill/ | sed 's/^/- /')
 
 ## 📄 Documentation
-- \`${PROJECT_NAME}-PCB-Top.pdf\` - Top layer layout
-- \`${PROJECT_NAME}-PCB-Bottom.pdf\` - Bottom layer layout
+- \`${PROJECT_NAME}-PCB-Complete.pdf\` - Complete PCB layout (5 pages: User drawings, Front copper, Back copper, Front assembly, Back assembly)
 
 ## 🖼️ Assembly Images
 $(ls -1 Export/Images/ | sed 's/^/- /')

.github/workflows/scripts/generate-production-summary.sh

@@ -55,8 +55,7 @@ $(ls -1 Export/Gerbers/ | sed 's/^/- /')
 $(ls -1 Export/Drill/ | sed 's/^/- /')
 
 ## 📄 Documentation
-- \`${PROJECT_NAME}-PCB-Top.pdf\` - Top layer layout
-- \`${PROJECT_NAME}-PCB-Bottom.pdf\` - Bottom layer layout
+- \`${PROJECT_NAME}-PCB-Complete.pdf\` - Complete PCB layout (5 pages: User drawings, Front copper, Back copper, Front assembly, Back assembly)
 
 ## 🖼️ Assembly Images
 $(ls -1 Export/Images/ | sed 's/^/- /')

.github/workflows/scripts/validate-export-files.sh

@@ -76,7 +76,7 @@ echo "🧪 Validating exported files for ${PROJECT_DESCRIPTION}..."
 cd "${PROJECT_PATH}/Export"
 
 # Check if critical files exist and have reasonable sizes
-critical_files="PDF/${PROJECT_NAME}-Schematics.pdf PDF/${PROJECT_NAME}-PCB-Top.pdf PDF/${PROJECT_NAME}-PCB-Bottom.pdf 3D/${PROJECT_NAME}.step"
+critical_files="PDF/${PROJECT_NAME}-Schematics.pdf PDF/${PROJECT_NAME}-PCB-Complete.pdf 3D/${PROJECT_NAME}.step"
 
 for file in $critical_files; do
   if [ -f "$file" ]; then