Fix NaN KiCad segments from through_obstacle trace route points

Author: mohan-bee

lib/pcb/stages/AddTracesStage.ts

@@ -22,6 +22,24 @@ export class AddTracesStage extends ConverterStage<CircuitJson, KicadPcb> {
     this.pcbTraces = this.ctx.db.pcb_trace.list()
   }
 
+  private getRoutePointPosition(point: any, edge: "start" | "end") {
+    const position =
+      typeof point.x === "number" && typeof point.y === "number"
+        ? { x: point.x, y: point.y }
+        : point[edge]
+
+    if (
+      typeof position?.x !== "number" ||
+      typeof position?.y !== "number" ||
+      !Number.isFinite(position.x) ||
+      !Number.isFinite(position.y)
+    ) {
+      return null
+    }
+
+    return position
+  }
+
   override _step(): void {
     const { kicadPcb, c2kMatPcb, pcbNetMap } = this.ctx
 
@@ -52,17 +70,28 @@ export class AddTracesStage extends ConverterStage<CircuitJson, KicadPcb> {
     for (let i = 0; i < trace.route.length - 1; i++) {
       const startPoint = trace.route[i]
       const endPoint = trace.route[i + 1]
+      const startPosition = this.getRoutePointPosition(startPoint, "end")
+      const endPosition = this.getRoutePointPosition(endPoint, "start")
+
+      if (!startPosition || !endPosition) continue
 
       // Transform points to KiCad coordinates
       const transformedStart = applyToPoint(c2kMatPcb, {
-        x: startPoint.x,
-        y: startPoint.y,
+        x: startPosition.x,
+        y: startPosition.y,
       })
       const transformedEnd = applyToPoint(c2kMatPcb, {
-        x: endPoint.x,
-        y: endPoint.y,
+        x: endPosition.x,
+        y: endPosition.y,
       })
 
+      if (
+        transformedStart.x === transformedEnd.x &&
+        transformedStart.y === transformedEnd.y
+      ) {
+        continue
+      }
+
       let netInfo: PcbNetInfo | undefined
       if (pcbNetMap) {
         let connectivityKey: string | undefined =

tests/pcb/repros/repro18-through-obstacle-route-point.test.tsx

@@ -0,0 +1,44 @@
+import { expect, test } from "bun:test"
+import type { CircuitJson } from "circuit-json"
+import { CircuitJsonToKicadPcbConverter } from "lib/pcb/CircuitJsonToKicadPcbConverter"
+
+const circuitJson: CircuitJson = [
+  {
+    type: "source_net",
+    source_net_id: "source_net_1",
+    name: "N1",
+    subcircuit_connectivity_map_key: "net1",
+  },
+  {
+    type: "source_trace",
+    source_trace_id: "source_trace_1",
+    connected_source_net_ids: ["source_net_1"],
+    subcircuit_connectivity_map_key: "net1",
+  },
+  {
+    type: "pcb_trace",
+    pcb_trace_id: "pcb_trace_1",
+    source_trace_id: "source_trace_1",
+    route: [
+      { route_type: "wire", x: 0, y: 0, width: 0.15, layer: "top" },
+      {
+        route_type: "through_obstacle",
+        start: { x: 0, y: 0 },
+        end: { x: 0, y: 0 },
+        from_layer: "top",
+        to_layer: "inner1",
+        width: 0.15,
+      },
+      { route_type: "wire", x: 1, y: 0, width: 0.15, layer: "inner1" },
+    ],
+  },
+] as any
+
+test("repro18: through_obstacle route points do not emit NaN segments", () => {
+  const converter = new CircuitJsonToKicadPcbConverter(circuitJson)
+  converter.runUntilFinished()
+  const output = converter.getOutputString()
+
+  expect(output).not.toContain("NaN")
+  expect(output).toContain("(end 101 100)")
+})