Zones now have a min thickness filled area parameter

change_log.txt

@@ -9,6 +9,11 @@ email address.
 ================================================================================
 ++pcbnew
     Some cleanup in dialog pad edition.
+    Added:
+    Zones now have a min thickness filled area parameter
+    that ensure a minimun width for filled copper areas
+    (areas below this min thickness are removed)
+    Shapes also are better
 
 
 2008-Nov-19 UPDATE Jerry Jacobs <jerkejacobs@gmail.com>

common/common_plotPS_functions.cpp

@@ -184,7 +184,7 @@ void PlotPolyPS( int nb_segm, int* coord, bool fill, int width )
 /* Draw a polygon ( a filled polygon if fill == 1 ) in POSTSCRIPT format
  * @param nb_segm = corner count
  * @param coord = corner list (a corner uses 2 int = X coordinate followed by Y  coordinate
- * @param fill :if == 0 : filled polygon
+ * @param fill :if true : filled polygon
  * @param  width = line width
  */
 {

pcbnew/class_zone.cpp

@@ -149,6 +149,10 @@ bool ZONE_CONTAINER::Save( FILE* aFile ) const
     if( ret < 2 )
         return false;
 
+    ret = fprintf( aFile, "ZMinThickness %d\n", m_ZoneMinThickness );
+    if( ret < 1 )
+        return false;
+
     ret = fprintf( aFile, "ZOptions %d %d %c %d %d\n", m_GridFillValue, m_ArcToSegmentsCount,
         m_DrawOptions ? 'S' : 'F', m_ThermalReliefGapValue, m_ThermalReliefCopperBridgeValue );
     if( ret < 3 )
@@ -332,6 +336,16 @@ int ZONE_CONTAINER::ReadDescr( FILE* aFile, int* aLineNum )
             }
         }
 
+        if( strnicmp( Line, "ZMinThickness", 13 ) == 0 )    // Min Thickness info found
+        {
+            int thickness;
+            text = Line + 13;
+            ret  = sscanf( text, "%d", &thickness );
+            if( ret < 1 )
+                error = true;
+            else
+               m_ZoneMinThickness = thickness;
+        }
 
         if( strnicmp( Line, "$POLYSCORNERS", 13 ) == 0  )  // Read the PolysList (polygons used for fill areas in the zone)
         {
@@ -522,8 +536,26 @@ void ZONE_CONTAINER::DrawFilledArea( WinEDA_DrawPanel* panel,
                 GRClosedPoly( &panel->m_ClipBox, DC, corners_count, CornersBuffer,
                     false, 0, color, color );
             else
+            {
+                // Draw outlines:
+                if ( m_ZoneMinThickness > 1 )
+                {
+                    int ilim = corners_count * 2;
+                    for (  int is = 0, ie = ilim-2; is < ilim; ie = is, is+=2 )
+                    {
+                        int x0 = CornersBuffer[is];
+                        int y0 = CornersBuffer[is+1];
+                        int x1 = CornersBuffer[ie];
+                        int y1 = CornersBuffer[ie+1];
+                        GRFillCSegm( &panel->m_ClipBox, DC,
+                                x0, y0, x1 , y1,
+                                m_ZoneMinThickness, color );
+                    }
+                }
+                // Draw areas:
                 GRPoly( &panel->m_ClipBox, DC, corners_count, CornersBuffer,
                     true, 0, color, color );
+            }
             corners_count = 0;
             ii = 0;
         }

pcbnew/class_zone.h

@@ -26,6 +26,7 @@ public:
     CPolyLine*            m_Poly;                           // outlines
     int                   m_CornerSelection;                // For corner moving, corner index to drag, or -1 if no selection
     int                   m_ZoneClearance;                  // clearance value
+    int                   m_ZoneMinThickness;               // Min thickness value in filled areas
     int                   m_GridFillValue;                  // Grid used for filling, 0 = use polygonal areas to fill
     int                   m_ArcToSegmentsCount;             // number of segments to convert a cirlce to a polygon (uses 16 or 32)
     int                   m_PadOption;                      //

pcbnew/class_zone_setting.cpp

@@ -26,6 +26,7 @@ ZONE_SETTING::ZONE_SETTING( void )
 {
     m_GridFillValue         = 250;                                  // Grid value for filling zone by segments, 0 to used polygons to fill
     m_ZoneClearance         = 200;                                  // Clearance value
+    m_ZoneMinThickness      = 0;                                    // Min thickness value in filled areas
     m_NetcodeSelection      = 0;                                    // Net code selection for the current zone
     m_CurrentZone_Layer     = 0;                                    // Layer used to create the current zone
     m_Zone_HatchingStyle    = CPolyLine::DIAGONAL_EDGE;             // Option to show the zone area (outlines only, short hatches or full hatches
@@ -47,6 +48,7 @@ void ZONE_SETTING::ImportSetting( const ZONE_CONTAINER& aSource )
 {
     m_GridFillValue         = aSource.m_GridFillValue;
     m_ZoneClearance         = aSource.m_ZoneClearance;
+    m_ZoneMinThickness      = aSource.m_ZoneMinThickness;
     m_NetcodeSelection      = aSource.GetNet();
     m_CurrentZone_Layer     = aSource.GetLayer();
     m_Zone_HatchingStyle    = aSource.GetHatchStyle();
@@ -68,9 +70,10 @@ void ZONE_SETTING::ExportSetting( ZONE_CONTAINER& aTarget )
 {
     aTarget.m_GridFillValue = m_GridFillValue;
     aTarget.m_ZoneClearance = m_ZoneClearance;
-    aTarget.SetNet(m_NetcodeSelection);
-    aTarget.SetLayer(m_CurrentZone_Layer);
-    aTarget.m_Poly->SetHatch(m_Zone_HatchingStyle);
+    aTarget.m_ZoneMinThickness = m_ZoneMinThickness;
+    aTarget.SetNet( m_NetcodeSelection );
+    aTarget.SetLayer( m_CurrentZone_Layer );
+    aTarget.m_Poly->SetHatch( m_Zone_HatchingStyle );
     aTarget.m_ArcToSegmentsCount = m_ArcToSegmentsCount;
     aTarget.m_DrawOptions = m_FilledAreasShowMode;
     aTarget.m_ThermalReliefGapValue = m_ThermalReliefGapValue;

pcbnew/class_zone_setting.h

@@ -19,6 +19,7 @@ class ZONE_SETTING
 public:
     int  m_GridFillValue;                               // Grid value for filling zone by segments, 0 to used polygons to fill
     int  m_ZoneClearance;                               // Clearance value
+    int  m_ZoneMinThickness;                            // Min thickness value in filled areas
     int  m_NetcodeSelection;                            // Net code selection for the current zone
     int  m_CurrentZone_Layer;                           // Layer used to create the current zone
     int  m_Zone_HatchingStyle;                          // Option to show the zone area (outlines only, short hatches or full hatches

pcbnew/dialog_copper_zones.cpp

@@ -64,17 +64,11 @@ void dialog_copper_zone::OnInitDialog( wxInitDialogEvent& event )
 
     SetFocus();     // Required under wxGTK if we want to demiss the dialog with the ESC key
 
-    wxString msg = _( "Zone clearance value:" ) + ReturnUnitSymbol( g_UnitMetric );
-    m_ClearanceValueTitle->SetLabel( msg );
+    wxString msg;
 
-    msg = _( "Grid :" ) + ReturnUnitSymbol( g_UnitMetric );
+    msg = m_GridCtrl->GetLabel() + ReturnUnitSymbol( g_UnitMetric );
     m_GridCtrl->SetLabel( msg );
 
-    msg = ReturnStringFromValue( g_UnitMetric,
-        m_Zone_Setting->m_ZoneClearance,
-        m_Parent->m_InternalUnits );
-    m_ZoneClearanceCtrl->SetValue( msg );
-
     if( g_Zone_45_Only )
         m_OrientEdgesOpt->SetSelection( 1 );
 
@@ -98,11 +92,18 @@ void dialog_copper_zone::OnInitDialog( wxInitDialogEvent& event )
 
     m_GridCtrl->SetSelection( selection );
 
+    AddUnitSymbol( *m_ClearanceValueTitle, g_UnitMetric );
     msg = ReturnStringFromValue( g_UnitMetric,
         m_Zone_Setting->m_ZoneClearance,
         m_Parent->m_InternalUnits );
     m_ZoneClearanceCtrl->SetValue( msg );
 
+    AddUnitSymbol( *m_MinThicknessValueTitle, g_UnitMetric );
+    msg = ReturnStringFromValue( g_UnitMetric,
+        m_Zone_Setting->m_ZoneMinThickness,
+        m_Parent->m_InternalUnits );
+    m_ZoneMinThicknessCtrl->SetValue( msg );
+
     switch( m_Zone_Setting->m_Zone_Pad_Options )
     {
     case PAD_NOT_IN_ZONE:           // Pads are not covered
@@ -324,6 +325,11 @@ bool dialog_copper_zone::AcceptOptions( bool aPromptForErrors, bool aUseExportab
     wxString txtvalue = m_ZoneClearanceCtrl->GetValue();
     m_Zone_Setting->m_ZoneClearance =
         ReturnValueFromString( g_UnitMetric, txtvalue, m_Parent->m_InternalUnits );
+
+    txtvalue = m_ZoneMinThicknessCtrl->GetValue();
+    m_Zone_Setting->m_ZoneMinThickness =
+        ReturnValueFromString( g_UnitMetric, txtvalue, m_Parent->m_InternalUnits );
+
     if( m_OrientEdgesOpt->GetSelection() == 0 )
         g_Zone_45_Only = FALSE;
     else

pcbnew/dialog_copper_zones_base.cpp

@@ -39,8 +39,8 @@ dialog_copper_zone_base::dialog_copper_zone_base( wxWindow* parent, wxWindowID i
 	
 	wxString m_GridCtrlChoices[] = { _("0.00000"), _("0.00000"), _("0.00000"), _("0.00000"), _("No grid (For tests only!)") };
 	int m_GridCtrlNChoices = sizeof( m_GridCtrlChoices ) / sizeof( wxString );
-	m_GridCtrl = new wxRadioBox( this,  ID_RADIOBOX_GRID_SELECTION, _("Grid Size for Filling:"), wxDefaultPosition, wxDefaultSize, m_GridCtrlNChoices, m_GridCtrlChoices, 1, wxRA_SPECIFY_COLS );
-	m_GridCtrl->SetSelection( 4 );
+	m_GridCtrl = new wxRadioBox( this,  ID_RADIOBOX_GRID_SELECTION, _("Grid Size for Filling"), wxDefaultPosition, wxDefaultSize, m_GridCtrlNChoices, m_GridCtrlChoices, 1, wxRA_SPECIFY_COLS );
+	m_GridCtrl->SetSelection( 1 );
 	m_FillOptionsBox->Add( m_GridCtrl, 0, wxALL|wxEXPAND, 5 );
 	
 	wxString m_PadInZoneOptChoices[] = { _("Include pads"), _("Thermal relief"), _("Exclude pads") };
@@ -119,13 +119,22 @@ dialog_copper_zone_base::dialog_copper_zone_base( wxWindow* parent, wxWindowID i
 	
 	m_OthersOptionsSizer->Add( m_ShowFilledAreasInSketchOpt, 0, wxALL, 5 );
 	
-	m_ClearanceValueTitle = new wxStaticText( this, wxID_ANY, _("Zone clearance value (mm):"), wxDefaultPosition, wxDefaultSize, 0 );
+	m_ClearanceValueTitle = new wxStaticText( this, wxID_ANY, _("Zone clearance value"), wxDefaultPosition, wxDefaultSize, 0 );
 	m_ClearanceValueTitle->Wrap( -1 );
 	m_OthersOptionsSizer->Add( m_ClearanceValueTitle, 0, wxTOP|wxRIGHT|wxLEFT, 5 );
 	
 	m_ZoneClearanceCtrl = new wxTextCtrl( this, wxID_ANY, wxEmptyString, wxDefaultPosition, wxDefaultSize, 0 );
 	m_OthersOptionsSizer->Add( m_ZoneClearanceCtrl, 0, wxEXPAND|wxBOTTOM|wxRIGHT|wxLEFT, 5 );
 	
+	m_MinThicknessValueTitle = new wxStaticText( this, wxID_ANY, _("Zone min thickness value"), wxDefaultPosition, wxDefaultSize, 0 );
+	m_MinThicknessValueTitle->Wrap( -1 );
+	m_OthersOptionsSizer->Add( m_MinThicknessValueTitle, 0, wxTOP|wxRIGHT|wxLEFT, 5 );
+	
+	m_ZoneMinThicknessCtrl = new wxTextCtrl( this, wxID_ANY, wxEmptyString, wxDefaultPosition, wxDefaultSize, 0 );
+	m_ZoneMinThicknessCtrl->SetToolTip( _("Value of minimun thickness of filled areas") );
+	
+	m_OthersOptionsSizer->Add( m_ZoneMinThicknessCtrl, 0, wxEXPAND|wxBOTTOM|wxRIGHT|wxLEFT, 5 );
+	
 	m_OutilinesBoxOpt->Add( m_OthersOptionsSizer, 1, wxEXPAND, 5 );
 	
 	m_MiddleBoxSizer->Add( m_OutilinesBoxOpt, 1, wxEXPAND, 5 );
@@ -173,6 +182,8 @@ dialog_copper_zone_base::dialog_copper_zone_base( wxWindow* parent, wxWindowID i
 	m_NetSortOptSizer->Add( m_staticText5, 0, wxTOP|wxRIGHT|wxLEFT, 5 );
 	
 	m_NetNameFilter = new wxTextCtrl( this, ID_TEXTCTRL_NETNAMES_FILTER, wxEmptyString, wxDefaultPosition, wxDefaultSize, 0 );
+	m_NetNameFilter->SetToolTip( _("Pattern in advanced mode, to filter net names in list\nNet names matching this pattern are not displayed") );
+	
 	m_NetSortOptSizer->Add( m_NetNameFilter, 0, wxEXPAND|wxBOTTOM|wxRIGHT|wxLEFT, 5 );
 	
 	m_RightBoxSizer->Add( m_NetSortOptSizer, 1, wxEXPAND, 5 );

pcbnew/dialog_copper_zones_base.h

@@ -73,6 +73,8 @@ class dialog_copper_zone_base : public wxDialog
 		wxCheckBox* m_ShowFilledAreasInSketchOpt;
 		wxStaticText* m_ClearanceValueTitle;
 		wxTextCtrl* m_ZoneClearanceCtrl;
+		wxStaticText* m_MinThicknessValueTitle;
+		wxTextCtrl* m_ZoneMinThicknessCtrl;
 		wxButton* m_ExportSetupButton;
 		
 		wxButton* m_OkButton;

pcbnew/pcbplot.h

@@ -146,7 +146,8 @@ void PlotTextePcb( TEXTE_PCB * pt_texte,int format_plot,int masque_layer);
 void PlotArc(int format_plot, wxPoint centre, int start_angle,int end_angle,
                     int rayon,int width);
 void PlotCircle(int format_plot,int width, wxPoint centre, int rayon);
-void PlotPolygon(int format_plot, bool filled, int nbpoints, int * coord);
+void PlotFilledPolygon(int format_plot, int nbpoints, int * coord);
+void PlotPolygon(int format_plot, int nbpoints, int * coord, int width);
 void Plot_1_texte( int format_plot,
                         const wxString & Text, int t_orient,
                         int width, int ox,int oy,int size_h,int size_v,
@@ -166,7 +167,8 @@ void PlotFilledAreas( ZONE_CONTAINER * aZone, int aFormat);
 /* PLOTGERB.CPP */
 void PlotGERBERLine(wxPoint start, wxPoint end, int width);
 void PlotCircle_GERBER( wxPoint centre, int rayon, int width);
-void PlotPolygon_GERBER(int nb_segm, int * coord, bool fill);
+void PlotFilledPolygon_GERBER(int nb_segm, int * coord);
+void PlotPolygon_GERBER(int nb_segm, int * coord, int width);
 void trace_1_contour_GERBER(wxPoint pos, wxSize size, wxSize delta,
                                         int penwidth, int orient);
     /* Trace 1 contour rectangulaire ou trapezoidal d'orientation quelconque

pcbnew/plot_rtn.cpp

@@ -550,7 +550,7 @@ void Plot_1_EdgeModule( int format_plot, EDGE_MODULE* PtEdge )
             *ptr++ = y;
         }
 
-        PlotPolygon( format_plot, TRUE, PtEdge->m_PolyCount, ptr_base );
+        PlotFilledPolygon( format_plot, PtEdge->m_PolyCount, ptr_base );
         free( ptr_base );
         break;
     }
@@ -748,7 +748,9 @@ void PlotFilledAreas( ZONE_CONTAINER * aZone, int aFormat )
         corners_count++;
         if( corner->end_contour )
         {   // Plot the current filled area
-            PlotPolygon( aFormat, true, corners_count, CornersBuffer );
+            PlotFilledPolygon( aFormat, corners_count, CornersBuffer );
+            if ( aZone->m_ZoneMinThickness > 0 )
+                PlotPolygon( aFormat, corners_count, CornersBuffer, aZone->m_ZoneMinThickness );
             corners_count = 0;
             ii = 0;
         }
@@ -848,22 +850,43 @@ void PlotCircle( int format_plot, int thickness, wxPoint centre, int radius )
 
 
 /**********************************************************************/
-void PlotPolygon( int format_plot, bool Filled, int nbpoints, int* coord )
+void PlotFilledPolygon( int format_plot, int nbpoints, int* coord )
 /**********************************************************************/
 /* plot a polygon */
 {
     switch( format_plot )
     {
     case PLOT_FORMAT_GERBER:
-        PlotPolygon_GERBER( nbpoints, coord, Filled );
+        PlotFilledPolygon_GERBER( nbpoints, coord );
         break;
 
     case PLOT_FORMAT_HPGL:
-        PlotPolyHPGL( nbpoints, coord, Filled );
+        PlotPolyHPGL( nbpoints, coord, true );
         break;
 
     case PLOT_FORMAT_POST:
-        PlotPolyPS( nbpoints, coord, Filled );
+        PlotPolyPS( nbpoints, coord, true );
+        break;
+    }
+}
+
+/**********************************************************************/
+void PlotPolygon( int format_plot, int nbpoints, int* coord, int width )
+/**********************************************************************/
+/* plot a polygon */
+{
+    switch( format_plot )
+    {
+    case PLOT_FORMAT_GERBER:
+        PlotPolygon_GERBER( nbpoints, coord, width );
+        break;
+
+    case PLOT_FORMAT_HPGL:
+        PlotPolyHPGL( nbpoints, coord, false, width );
+        break;
+
+    case PLOT_FORMAT_POST:
+        PlotPolyPS( nbpoints, coord, false, width );
         break;
     }
 }

pcbnew/plotgerb.cpp

@@ -632,7 +632,7 @@ void trace_1_pad_TRAPEZE_GERBER( wxPoint pos, wxSize size, wxSize delta,
         PlotGERBERLine( polygon[3], polygon[0], plotLine_width );
     }
     else
-        PlotPolygon_GERBER( 4, coord, TRUE );
+        PlotFilledPolygon_GERBER( 4, coord );
 }
 
 
@@ -701,7 +701,7 @@ void PlotCircle_GERBER( wxPoint centre, int rayon, int epaisseur )
 
 
 /***************************************************************/
-void PlotPolygon_GERBER( int nb_segm, int* coord, bool fill )
+void PlotFilledPolygon_GERBER( int nb_segm, int* coord )
 /***************************************************************/
 {
     int     ii;
@@ -730,6 +730,30 @@ void PlotPolygon_GERBER( int nb_segm, int* coord, bool fill )
 }
 
 
+/***************************************************************/
+void PlotPolygon_GERBER( int nb_segm, int* coord, int width )
+/***************************************************************/
+{
+    wxPoint start, end, startpoint;
+    startpoint.x = *coord++;
+    startpoint.y = *coord++;
+    start = startpoint;
+    for( int ii = 0; ii < nb_segm-1; ii++ )
+    {
+        end.x = *coord;
+        coord++;
+        end.y = *coord;
+        coord++;
+        PlotGERBERLine(start, end, width );
+        start = end;
+    }
+
+    if ( startpoint != end )    // Close poly
+        PlotGERBERLine(end, startpoint, width );
+
+}
+
+
 /*******************************************************/
 D_CODE* get_D_code( int dx, int dy, int type, int drill )
 /*******************************************************/

pcbnew/zones_convert_brd_items_to_polygons.cpp

@@ -52,10 +52,11 @@ double     s_Correction; /* mult coeff used to enlarge rounded and oval pads (an
                           */
 
 /** function AddClearanceAreasPolygonsToPolysList
+ * Supports a min thickness area constraint.
  * Add non copper areas polygons (pads and tracks with clearence)
- * to a filled copper area
- * used in BuildFilledPolysListData when calculating filled areas in a zone
- * Non copper areas are pads and track and their clearance area
+ * to the filled copper area found
+ * in BuildFilledPolysListData after calculating filled areas in a zone
+ * Non filled copper areas are pads and track and their clearance areas
  * The filled copper area must be computed just before.
  * BuildFilledPolysListData() call this function just after creating the
  *  filled copper area polygon (without clearence areas
@@ -64,10 +65,17 @@ double     s_Correction; /* mult coeff used to enlarge rounded and oval pads (an
  *       this means the created polygons have no holes (hole are linked to outer outline by double overlapped segments
  *       and are therefore compatible with draw functions (DC draw polygons and Gerber or PS outputs)
  * 2 - Add the main outline (zone outline) in group A
- * 3 - Add all non filled areas (pads, tracks) in group B
- * 4 - calculates the polygon A - B
- * 5 - put resulting list of polygons (filled areas) in m_FilledPolysList
- * 6 - Remove insulated copper islands
+ * 3 - Creates a correction using BOOL_CORRECTION operation to inflate the resulting area
+ *     with m_ZoneMinThickness/2 value.
+ *     The result is areas with a margin of m_ZoneMinThickness/2
+ *     When drawing outline with segments having a thickness of m_ZoneMinThickness, the outlines wilm
+ *     match exactly the initial outlines
+ * 4 - recreates the same Bool_Engine, with no correction
+ * 3 - Add the main outline (zone outline) in group A
+ * 4 - Add all non filled areas (pads, tracks) in group B with a clearance of m_Clearance + m_ZoneMinThickness/2
+ * 5 - calculates the polygon A - B
+ * 6 - put resulting list of polygons (filled areas) in m_FilledPolysList
+ * 7 - Remove insulated copper islands
  */
 void ZONE_CONTAINER::AddClearanceAreasPolygonsToPolysList( BOARD* aPcb )
 {
@@ -87,16 +95,19 @@ void ZONE_CONTAINER::AddClearanceAreasPolygonsToPolysList( BOARD* aPcb )
     /* Uses a kbool engine to add holes in the m_FilledPolysList polygon.
      * Because this function is called just after creating the m_FilledPolysList,
      * only one polygon is in list.
-     * (initial holes in zonesare linked into outer contours by double overlapping segments).
-     * after adding holes, many polygons could be exist in this list.
+     * (initial holes in zones are linked into outer contours by double overlapping segments).
+     * because after adding holes, many polygons could be exist in this list.
      */
 
     Bool_Engine* booleng = new Bool_Engine();
-
     ArmBoolEng( booleng, true );
 
-    /* Add the main polygon (i.e. the filled area using only one outline)
-     * in GroupA in Bool_Engine
+    /* First, Add the main polygon (i.e. the filled area using only one outline)
+     * in GroupA in Bool_Engine to do a BOOL_CORRECTION operation
+     * to reserve a m_ZoneMinThickness/2 margind around the outlines and holes
+     * the margind will be filled when redraw outilnes with segments having a whidth set to
+     * m_ZoneMinThickness
+     * so m_ZoneMinThickness is the min thickness of the filled zones areas
      */
     unsigned corners_count = m_FilledPolysList.size();
     unsigned ic = 0;
@@ -112,9 +123,59 @@ void ZONE_CONTAINER::AddClearanceAreasPolygonsToPolysList( BOARD* aPcb )
 
         booleng->EndPolygonAdd();
     }
+    booleng->SetCorrectionFactor( (double) -m_ZoneMinThickness/2 );
+    booleng->Do_Operation( BOOL_CORRECTION );
+
+    /* No copy the new outline in m_FilledPolysList */
+    m_FilledPolysList.clear();
+    while( booleng->StartPolygonGet() )
+    {
+        CPolyPt corner( 0, 0, false );
+        while( booleng->PolygonHasMorePoints() )
+        {
+            corner.x = (int) booleng->GetPolygonXPoint();
+            corner.y = (int) booleng->GetPolygonYPoint();
+            corner.end_contour = false;
+            m_FilledPolysList.push_back( corner );
+        }
+
+        corner.end_contour = true;
+        m_FilledPolysList.pop_back();
+        m_FilledPolysList.push_back( corner );
+        booleng->EndPolygonGet();
+    }
+    delete booleng;
+
+    /* Second, Add the main (corrected) polygon (i.e. the filled area using only one outline)
+     * in GroupA in Bool_Engine to do a BOOL_A_SUB_B operation
+     * All areas to remove will be put in GroupB in Bool_Engine
+     */
+    booleng = new Bool_Engine();
+    ArmBoolEng( booleng, true );
+
+    /* Add the main corrected polygon (i.e. the filled area using only one outline)
+     * in GroupA in Bool_Engine
+     */
+    corners_count = m_FilledPolysList.size();
+    ic = 0;
+    if( booleng->StartPolygonAdd( GROUP_A ) )
+    {
+        for( ; ic < corners_count; ic++ )
+        {
+            CPolyPt* corner = &m_FilledPolysList[ic];
+            booleng->AddPoint( corner->x, corner->y );
+            if( corner->end_contour )
+                break;
+        }
+
+        booleng->EndPolygonAdd();
+    }
+
 
     // Calculates the clearance value that meet DRC requirements
     int      clearance = max( m_ZoneClearance, g_DesignSettings.m_TrackClearence );
+    clearance += m_ZoneMinThickness/2;
+
 
     /* Add holes (i.e. tracks and pads areas as polygons outlines)
      * in GroupB in Bool_Engine
@@ -155,7 +216,8 @@ void ZONE_CONTAINER::AddClearanceAreasPolygonsToPolysList( BOARD* aPcb )
                 item_boundingbox.Inflate( m_ThermalReliefGapValue, m_ThermalReliefGapValue );
                 if( item_boundingbox.Intersects( zone_boundingbox ) )
                     AddThermalReliefPadPolygon( booleng, *pad,
-                        m_ThermalReliefGapValue, m_ThermalReliefCopperBridgeValue );
+                        m_ThermalReliefGapValue/* + (m_ZoneMinThickness/2)*/,
+                        m_ThermalReliefCopperBridgeValue /*- m_ZoneMinThickness*/ );
                 break;
 
             case PAD_IN_ZONE:
@@ -401,6 +463,9 @@ void    AddThermalReliefPadPolygon( Bool_Engine* aBooleng,
 
     int     delta = 3600 / s_CircleToSegmentsCount; // rot angle in 0.1 degree
 
+    if ( aCopperThickness < 0 )
+        aCopperThickness = 0;
+
     copper_tickness.x = min( dx, aCopperThickness );
     copper_tickness.y = min( dy, aCopperThickness );
 

polygon/PolyLine.cpp

@@ -541,7 +541,7 @@ void ArmBoolEng( Bool_Engine* aBooleng, bool aConvertHoles )
     double DGRID = 1.0;     // round coordinate X or Y value in calculations to this (initial value = 1000.0 in kbool example)
                             // Note: in kicad, coordinates are already integer so DGRID can be set to 1
 
-    double MARGE = 0.1;     // snap with in this range points to lines in the intersection routines
+    double MARGE = 0.001;     // snap with in this range points to lines in the intersection routines
                             // should always be > DGRID  a  MARGE >= 10*DGRID is ok
                             // this is also used to remove small segments and to decide when
                             // two segments are in line. ( initial value = 0.001 )
@@ -559,7 +559,7 @@ void ArmBoolEng( Bool_Engine* aBooleng, bool aConvertHoles )
         Another scaling with Grid is applied on top of it to create space in the integer number for
 		even smaller numbers.
    */
-    int GRID = 100;       // initial value = 10000 in kbool example
+    int GRID = 10000;       // initial value = 10000 in kbool example
 
     aBooleng->SetMarge( MARGE );
     aBooleng->SetGrid( GRID );