First tests about copper zones filled by polygons, without grid (see changelog)

Only for tests! not for production.

change_log.txt

@@ -5,16 +5,29 @@ Started 2007-June-11
 Please add newer entries at the top, list the date and your name with
 email address.
 
+2008-oct-02 UPDATE Jean-Pierre Charras <jean-pierre.charras@inpg.fr>
+================================================================================
++pcbnew:
+    First tests about copper zones filled without grid (by polygons)
+    Currently for eyes and tests only.
+    To select this feature choose No Grid in zone grid filling.
+    Work in progress:
+    currently : not implemented:
+        thermal reliefs (pads are always covered by copper zones).
+        texts on copper zones.
+        Removing insulated copper islands.
+
 2008-Oct-1 UPDATE Dick Hollenbeck <dick@softplc.com>
 ================================================================================
 +pcbnew
     gen_modules_placefile.cpp: backed out of the "Cu & Cmp" centric terminology
     and moved towards using layer names which are BOARD specific.
 
+
 2008-Sep-26 UPDATE Jean-Pierre Charras <jean-pierre.charras@inpg.fr>
 ================================================================================
 +pcbnew:
-    more about use polygons in zone fill algos on techinals layers:
+    more about use polygons in zone fill algos on technicals layers:
     plot Ok. holes are handled
 
 2008-Sep-26 UPDATE Jean-Pierre Charras <jean-pierre.charras@inpg.fr>

include/build_version.h

@@ -9,7 +9,7 @@ COMMON_GLOBL wxString g_BuildVersion
 #    include "config.h"
      (wxT(KICAD_SVN_VERSION))
 #  else
-     (wxT("(20080920)")) /* main program version */
+     (wxT("(20081002-unstable)")) /* main program version */
 #  endif
 #endif
 ;
@@ -20,7 +20,7 @@ COMMON_GLOBL wxString g_BuildAboutVersion
 #    include "config.h"
      (wxT(KICAD_ABOUT_VERSION))
 #  else
-     (wxT("(20080920)")) /* svn date & rev (normally overridden) */
+     (wxT("(20081002-unstable)")) /* svn date & rev (normally overridden) */
 #  endif
 #endif
 ;

pcbnew/CMakeLists.txt

@@ -139,9 +139,11 @@ set(PCBNEW_SRCS
     via_edit.cpp
     work.cpp
     xchgmod.cpp
-    zone_filling_algorithm.cpp
     zones_by_polygon.cpp
-    zones_test_and_combine_areas.cpp)
+    zones_convert_brd_items_to_polygons.cpp
+    zone_filling_algorithm.cpp
+    zones_test_and_combine_areas.cpp
+    )
 
 set(PCBNEW_EXTRA_SRCS
     ../share/drawframe.cpp

pcbnew/class_zone.h

@@ -143,9 +143,24 @@ public:
      * Build m_FilledPolysList data from real outlines (m_Poly)
      * in order to have drawable (and plottable) filled polygons
      * drawable filled polygons are polygons without hole
+     * @param aPcb: the current board (can be NULL for non copper zones)
      * @return number of polygons
+     * This function does not add holes for pads and tracks but calls
+     * AddClearanceAreasPolygonsToPolysList() to do that for copper layers
      */
-    int  BuildFilledPolysListData( void );
+    int  BuildFilledPolysListData( BOARD * aPcb );
+
+    /** function AddClearanceAreasPolygonsToPolysList
+     * 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
+     * The filled copper area must be computed before
+     * BuildFilledPolysListData() call this function just after creating the 
+     *  filled copper area polygon (without clearence areas
+     * @param aPcb: the current board
+     */
+    void AddClearanceAreasPolygonsToPolysList( BOARD * aPcb );
 
     /**
      * Function HitTestForCorner

pcbnew/dialog_zones_by_polygon.cpp

@@ -48,6 +48,8 @@ IMPLEMENT_DYNAMIC_CLASS( WinEDA_ZoneFrame, wxDialog )
 BEGIN_EVENT_TABLE( WinEDA_ZoneFrame, wxDialog )
 
 ////@begin WinEDA_ZoneFrame event table entries
+    EVT_INIT_DIALOG( WinEDA_ZoneFrame::OnInitDialog )
+
     EVT_BUTTON( wxID_OK, WinEDA_ZoneFrame::OnOkClick )
 
     EVT_BUTTON( wxID_CANCEL, WinEDA_ZoneFrame::OnCancelClick )
@@ -133,12 +135,8 @@ bool WinEDA_ZoneFrame::Create( wxWindow*       parent,
 
 void WinEDA_ZoneFrame::CreateControls()
 {
-    BOARD*  board = m_Parent->m_Pcb;
-
-    SetFont( *g_DialogFont );
-
 ////@begin WinEDA_ZoneFrame content construction
-    // Generated by DialogBlocks, 24/01/2008 11:39:58 (unregistered)
+    // Generated by DialogBlocks, 02/10/2008 15:53:10 (unregistered)
 
     WinEDA_ZoneFrame* itemDialog1 = this;
 
@@ -156,6 +154,7 @@ void WinEDA_ZoneFrame::CreateControls()
     m_GridCtrlStrings.Add(_("0.00000"));
     m_GridCtrlStrings.Add(_("0.00000"));
     m_GridCtrlStrings.Add(_("0.00000"));
+    m_GridCtrlStrings.Add(_("No Grid (For tests only!)"));
     m_GridCtrl = new wxRadioBox( itemDialog1, ID_RADIOBOX_GRID_SELECTION, _("Grid Size for Filling:"), wxDefaultPosition, wxDefaultSize, m_GridCtrlStrings, 1, wxRA_SPECIFY_COLS );
     m_GridCtrl->SetSelection(0);
     itemBoxSizer4->Add(m_GridCtrl, 0, wxGROW|wxALL, 5);
@@ -246,7 +245,19 @@ void WinEDA_ZoneFrame::CreateControls()
     m_NetSortingOption->SetValidator( wxGenericValidator(& m_NetSorting) );
 ////@end WinEDA_ZoneFrame content construction
 
-    // Initialise options
+}
+
+
+/*!
+ * wxEVT_INIT_DIALOG event handler for ID_DIALOG
+ */
+// Initialise dialog options
+void WinEDA_ZoneFrame::OnInitDialog( wxInitDialogEvent& event )
+{
+    BOARD*  board = m_Parent->m_Pcb;
+
+    SetFont( *g_DialogFont );
+
     wxString title = _( "Zone clearance value:" ) + ReturnUnitSymbol( g_UnitMetric );
     m_ClearanceValueTitle->SetLabel( title );
 
@@ -266,7 +277,7 @@ void WinEDA_ZoneFrame::CreateControls()
     static const int GridList[4] = { 25, 50, 100, 250 };
     int selection = 0;
 
-    for( unsigned ii = 0; ii < (unsigned) m_GridCtrl->GetCount(); ii++ )
+    for( unsigned ii = 0; ii < 4; ii++ )
     {
         wxString msg = ReturnStringFromValue( g_UnitMetric,
                                               GridList[ii],
@@ -409,6 +420,10 @@ void WinEDA_ZoneFrame::CreateControls()
             }
         }
     }
+    if (GetSizer())
+    {
+        GetSizer()->SetSizeHints(this);
+    }
 }
 
 
@@ -520,6 +535,11 @@ bool WinEDA_ZoneFrame::AcceptOptions(bool aPromptForErrors)
     case 3:
         g_GridRoutingSize = 250;
         break;
+    case 4:
+        wxMessageBox( wxT(
+"You are using No grid for filling zones\nThis is currently in development and for tests only.\n Do not use for production"));
+        g_GridRoutingSize = 0;
+        break;
     }
 
     wxString txtvalue = m_ZoneClearanceCtrl->GetValue();
@@ -607,3 +627,5 @@ void WinEDA_ZoneFrame::OnOkClick( wxCommandEvent& event )
         EndModal( ZONE_OK );
 }
 
+
+

pcbnew/dialog_zones_by_polygon.h

@@ -77,7 +77,7 @@ public:
     /// Constructors
     WinEDA_ZoneFrame( );
     WinEDA_ZoneFrame( WinEDA_PcbFrame* parent,
-						ZONE_CONTAINER * zone_container = NULL,
+						ZONE_CONTAINER * zone_container,
 						wxWindowID id = SYMBOL_WINEDA_ZONEFRAME_IDNAME,
 						const wxString& caption = SYMBOL_WINEDA_ZONEFRAME_TITLE,
 						const wxPoint& pos = SYMBOL_WINEDA_ZONEFRAME_POSITION,
@@ -92,6 +92,9 @@ public:
 
 ////@begin WinEDA_ZoneFrame event handler declarations
 
+    /// wxEVT_INIT_DIALOG event handler for ID_DIALOG
+    void OnInitDialog( wxInitDialogEvent& event );
+
     /// wxEVT_COMMAND_BUTTON_CLICKED event handler for wxID_OK
     void OnOkClick( wxCommandEvent& event );
 

pcbnew/dialog_zones_by_polygon.pjd

@@ -136,6 +136,7 @@
         <long name="locked">0</long>
         <string name="template-name">""</string>
         <bool name="dirty">1</bool>
+        <long name="makefile-last-written">-8519680</long>
         <string name="Compiler name">""</string>
         <string name="Build mode">"Debug"</string>
         <string name="Unicode mode">"ANSI"</string>
@@ -177,6 +178,8 @@
         <string name="wxWidgets build command">"%AUTO%"</string>
         <string name="wxWidgets clean command">"%AUTO%"</string>
         <string name="PATH variable">"%AUTO%"</string>
+        <bool name="Suppress source rules">0</bool>
+        <bool name="Enable makefile generation">1</bool>
       </document>
     </document>
   </data>
@@ -218,6 +221,7 @@
           <string name="id-suffix">""</string>
           <long name="use-xrc">0</long>
           <long name="working-mode">0</long>
+          <string name="event-handler-0">"wxEVT_INIT_DIALOG|OnInitDialog|NONE||WinEDA_ZoneFrame"</string>
           <string name="proxy-Id name">"ID_DIALOG"</string>
           <long name="proxy-Id value">10000</long>
           <string name="proxy-Class">"WinEDA_ZoneFrame"</string>
@@ -248,7 +252,6 @@
           <bool name="proxy-wxDEFAULT_DIALOG_STYLE">0</bool>
           <bool name="proxy-wxCAPTION">1</bool>
           <bool name="proxy-wxRESIZE_BORDER">0</bool>
-          <bool name="proxy-wxTHICK_FRAME">0</bool>
           <bool name="proxy-wxSYSTEM_MENU">1</bool>
           <bool name="proxy-wxSTAY_ON_TOP">0</bool>
           <bool name="proxy-wxDIALOG_NO_PARENT">0</bool>
@@ -369,7 +372,7 @@
                   <string name="proxy-Member variable name">"m_GridCtrl"</string>
                   <string name="proxy-Label">"Grid Size for Filling:"</string>
                   <long name="proxy-Major dimension count">1</long>
-                  <string name="proxy-Items">"0.00000|0.00000|0.00000|0.00000"</string>
+                  <string name="proxy-Items">"0.00000|0.00000|0.00000|0.00000|No Grid (For tests only!)"</string>
                   <long name="proxy-Initial value">0</long>
                   <string name="proxy-Help text">""</string>
                   <string name="proxy-Tooltip text">""</string>

pcbnew/ioascii.cpp

@@ -1011,9 +1011,10 @@ int WinEDA_PcbFrame::ReadPcbFile( FILE* File, bool Append )
 
 #ifdef PCBNEW
     if( m_Pcb->m_ZoneDescriptorList.size() > 0 )
-    {   // Build filled areas
+    {
+        // Build filled areas
         for( unsigned ia = 0; ia < m_Pcb->m_ZoneDescriptorList.size(); ia++ )
-            m_Pcb->m_ZoneDescriptorList[ia]->BuildFilledPolysListData( );
+            m_Pcb->m_ZoneDescriptorList[ia]->BuildFilledPolysListData( m_Pcb );
     }
 
     // Build connectivity info

pcbnew/makefile.include

@@ -11,7 +11,9 @@ EXTRACPPFLAGS += -DPCBNEW  -fno-strict-aliasing -I./ -Ibitmaps -I../include -I..
 
 LIBVIEWER3D = ../3d-viewer/3d-viewer.a
 
-ZONE_FILES = zones_by_polygon.o zones_test_and_combine_areas.o zone_filling_algorithm.o
+ZONE_FILES = zones_by_polygon.o zones_test_and_combine_areas.o\
+        zone_filling_algorithm.o\
+        zones_convert_brd_items_to_polygons.o
 
 SPECCTRA_TOOLS = specctra.o specctra_export.o dsn.o specctra_import.o
 

pcbnew/zones_by_polygon.cpp

@@ -518,7 +518,7 @@ int WinEDA_PcbFrame::Begin_Zone( wxDC* DC )
             zone->SetLayer( ( (PCB_SCREEN*) GetScreen() )->m_Active_Layer );
             if( zone->IsOnCopperLayer() )
             {   // Put a zone on a copper layer
-                WinEDA_ZoneFrame* frame = new WinEDA_ZoneFrame( this );
+                WinEDA_ZoneFrame* frame = new WinEDA_ZoneFrame( this, zone  );
                 diag = frame->ShowModal();
                 frame->Destroy();
             }
@@ -758,7 +758,7 @@ void WinEDA_PcbFrame::Edit_Zone_Params( wxDC* DC, ZONE_CONTAINER* zone_container
     DrawPanel->m_IgnoreMouseEvents = TRUE;
     if( zone_container->GetLayer() < FIRST_NO_COPPER_LAYER )
     {   // edit a zone on a copper layer
-        WinEDA_ZoneFrame* frame = new WinEDA_ZoneFrame( this );
+        WinEDA_ZoneFrame* frame = new WinEDA_ZoneFrame( this, zone_container );
         diag = frame->ShowModal();
         frame->Destroy();
     }
@@ -889,8 +889,18 @@ int WinEDA_PcbFrame::Fill_Zone( wxDC* DC, ZONE_CONTAINER* zone_container, bool v
     Affiche_1_Parametre( this, 22, _( "NetName" ), msg, RED );
     wxBusyCursor dummy;     // Shows an hourglass cursor (removed by its destructor)
 
-    zone_container->m_GridFillValue = g_GridRoutingSize;
-    int          error_level = zone_container->Fill_Zone( this, DC, verbose );
+    int          error_level = 0;
+    if( zone_container->m_GridFillValue == 0 )
+    {
+        zone_container->BuildFilledPolysListData( m_Pcb );
+        if ( DC )
+            DrawPanel->Refresh();
+    }
+    else
+    {
+        zone_container->m_GridFillValue = g_GridRoutingSize;
+        error_level = zone_container->Fill_Zone( this, DC, verbose );
+    }
 
     GetScreen()->SetModify();
 

pcbnew/zones_convert_brd_items_to_polygons.cpp

+using namespace std;
+
+#include <math.h>
+#include <vector>
+
+#include "fctsys.h"
+#include "common.h"
+#include "pcbnew.h"
+#include "trigo.h"
+
+#include "zones.h"
+
+
+#include "PolyLine.h"
+
+void    AddTrackWithClearancePolygon( Bool_Engine* aBooleng,
+                                      TRACK& aTrack, int aClearanceValue );
+void    AddPadWithClearancePolygon( Bool_Engine* aBooleng,
+                                    D_PAD& aPad, int aClearanceValue,
+                                    bool bThermal, int spoke_w );
+void    AddRoundedEndsSegmentPolygon( Bool_Engine* aBooleng,
+                                      wxPoint aStart, wxPoint aEnd,
+                                      int aWidth );
+
+/* how many segments are used to create a polygon from a circle: */
+static int s_CircleToSegmentsCount = 16;
+
+/** function AddClearanceAreasPolygonsToPolysList
+ * 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
+ * The filled copper area must be computed just before.
+ * BuildFilledPolysListData() call this function just after creating the
+ *  filled copper area polygon (without clearence areas
+ * to do that this function:
+ * 1 - creates aBool_Engine,with option: holes are linked into outer contours by double overlapping segments
+ * 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
+ */
+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.
+     */
+
+
+    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
+     */
+    unsigned corners_count = m_FilledPolysList.size();
+    unsigned 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();
+    }
+
+    /* Add holes (i.e. tracks and pads areas as polygons outlines)
+     * in GroupB in Bool_Engine
+     * First : Add pads
+     */
+    for( MODULE* module = aPcb->m_Modules;  module;  module = module->Next() )
+    {
+        for( D_PAD* pad = module->m_Pads; pad != NULL; pad = pad->Next() )
+        {
+            if( !pad->IsOnLayer( GetLayer() ) )
+                continue;
+            AddPadWithClearancePolygon( booleng, *pad, m_ZoneClearance,
+                                        false, 0 );
+        }
+    }
+
+    /* Add holes (i.e. tracks and pads areas as polygons outlines)
+     * in GroupB in Bool_Engine
+     * Next : Add tracks and vias
+     */
+    for( TRACK* track = aPcb->m_Track;  track;  track = track->Next() )
+    {
+        if( !track->IsOnLayer( GetLayer() ) )
+            continue;
+        AddTrackWithClearancePolygon( booleng, *track, m_ZoneClearance );
+    }
+
+    // Draw graphic items (copper texts) and board edges
+    for( BOARD_ITEM* item = aPcb->m_Drawings;  item;  item = item->Next() )
+    {
+        switch( item->Type() )
+        {
+        case TYPEDRAWSEGMENT:
+
+            // TODO: add segment
+            break;
+
+        case TYPETEXTE:
+
+            // TODO: add rectangular area
+            break;
+
+        default:
+            break;
+        }
+    }
+
+    /* compute copper areas */
+    booleng->Do_Operation( BOOL_A_SUB_B );
+
+    /* put these areas 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;
+}
+
+
+/** Function AddPadPolygonWithPadClearance
+ * Add a polygon cutout for a pad in a zone area
+ * Convert arcs and circles to multiple straight lines
+ */
+void AddPadWithClearancePolygon( Bool_Engine* aBooleng,
+                                 D_PAD& aPad, int aClearanceValue,
+                                 bool bThermal, int spoke_w )
+{
+    wxPoint corner_position;
+    int     ii, angle;
+    int     dx = (aPad.m_Size.x / 2) + aClearanceValue;
+    int     dy = (aPad.m_Size.y / 2) + aClearanceValue;
+
+    int     delta = 3600 / s_CircleToSegmentsCount; // rot angle in 0.1 degree
+
+    if( !bThermal )
+    {
+        switch( aPad.m_PadShape )
+        {
+        case PAD_CIRCLE:
+            if( aBooleng->StartPolygonAdd( GROUP_B ) )
+            {
+                for( ii = 0; ii < s_CircleToSegmentsCount; ii++ )
+                {
+                    corner_position = wxPoint( dx, 0 );
+                    angle = ii * delta;
+                    RotatePoint( &corner_position, angle );
+                    corner_position += aPad.ReturnShapePos();
+                    aBooleng->AddPoint( corner_position.x, corner_position.y );
+                }
+
+                aBooleng->EndPolygonAdd();
+            }
+            break;
+
+        case PAD_OVAL:
+        case PAD_RECT:
+            if( aBooleng->StartPolygonAdd( GROUP_B ) )
+            {
+                angle = aPad.m_Orient;
+                corner_position = wxPoint( -dx, -dy );
+                RotatePoint( &corner_position, angle );
+                corner_position += aPad.ReturnShapePos();
+                aBooleng->AddPoint( corner_position.x, corner_position.y );
+
+                corner_position = wxPoint( -dx, +dy );
+                RotatePoint( &corner_position, angle );
+                corner_position += aPad.ReturnShapePos();
+                aBooleng->AddPoint( corner_position.x, corner_position.y );
+
+                corner_position = wxPoint( +dx, +dy );
+                RotatePoint( &corner_position, angle );
+                corner_position += aPad.ReturnShapePos();
+                aBooleng->AddPoint( corner_position.x, corner_position.y );
+
+                corner_position = wxPoint( +dx, -dy );
+                RotatePoint( &corner_position, angle );
+                corner_position += aPad.ReturnShapePos();
+                aBooleng->AddPoint( corner_position.x, corner_position.y );
+
+                aBooleng->EndPolygonAdd();
+            }
+            break;
+        }
+    }
+    else
+    {
+        // thermal relief (from FreePCB: must be converted to pcbnew data)
+#if 0
+        if( type == PAD_ROUND || (type == PAD_NONE && hole_w > 0) )
+        {
+            // draw 4 "wedges"
+            double r = max( w / 2 + fill_clearance, hole_w / 2 + hole_clearance );
+            double start_angle = asin( spoke_w / (2.0 * r) );
+            double th1, th2, corner_x, corner_y;
+            th1 = th2 = corner_x = corner_y = 0; // gcc warning fix
+            for( int i = 0; i<4; i++ )
+            {
+                if( i == 0 )
+                {
+                    corner_x = spoke_w / 2;
+                    corner_y = spoke_w / 2;
+                    th1 = start_angle;
+                    th2 = pi / 2.0 - start_angle;
+                }
+                else if( i == 1 )
+                {
+                    corner_x = -spoke_w / 2;
+                    corner_y = spoke_w / 2;
+                    th1 = pi / 2.0 + start_angle;
+                    th2 = pi - start_angle;
+                }
+                else if( i == 2 )
+                {
+                    corner_x = -spoke_w / 2;
+                    corner_y = -spoke_w / 2;
+                    th1 = -pi + start_angle;
+                    th2 = -pi / 2.0 - start_angle;
+                }
+                else if( i == 3 )
+                {
+                    corner_x = spoke_w / 2;
+                    corner_y = -spoke_w / 2;
+                    th1 = -pi / 2.0 + start_angle;
+                    th2 = -start_angle;
+                }
+                AppendCorner( to_int( x + corner_x ), to_int( y + corner_y ), STRAIGHT, 0 );
+                AppendCorner( to_int( x + r * cos( th1 ) ), to_int( y + r * sin(
+                                                                       th1 ) ), STRAIGHT, 0 );
+                AppendCorner( to_int( x + r * cos( th2 ) ), to_int( y + r * sin(
+                                                                       th2 ) ), ARC_CCW, 0 );
+                Close( STRAIGHT );
+            }
+        }
+        else if( type == PAD_SQUARE || type == PAD_RECT
+                 || type == PAD_RRECT || type == PAD_OVAL )
+        {
+            // draw 4 rectangles
+            int xL = x - dx;
+            int xR = x - spoke_w / 2;
+            int yB = y - dy;
+            int yT = y - spoke_w / 2;
+            AppendCorner( xL, yB, STRAIGHT, 0 );
+            AppendCorner( xR, yB, STRAIGHT, 0 );
+            AppendCorner( xR, yT, STRAIGHT, 0 );
+            AppendCorner( xL, yT, STRAIGHT, 0 );
+            Close( STRAIGHT );
+            xL = x + spoke_w / 2;
+            xR = x + dx;
+            AppendCorner( xL, yB, STRAIGHT, 0 );
+            AppendCorner( xR, yB, STRAIGHT, 0 );
+            AppendCorner( xR, yT, STRAIGHT, 0 );
+            AppendCorner( xL, yT, STRAIGHT, 0 );
+            Close( STRAIGHT );
+            xL = x - dx;
+            xR = x - spoke_w / 2;
+            yB = y + spoke_w / 2;
+            yT = y + dy;
+            AppendCorner( xL, yB, STRAIGHT, 0 );
+            AppendCorner( xR, yB, STRAIGHT, 0 );
+            AppendCorner( xR, yT, STRAIGHT, 0 );
+            AppendCorner( xL, yT, STRAIGHT, 0 );
+            Close( STRAIGHT );
+            xL = x + spoke_w / 2;
+            xR = x + dx;
+            AppendCorner( xL, yB, STRAIGHT, 0 );
+            AppendCorner( xR, yB, STRAIGHT, 0 );
+            AppendCorner( xR, yT, STRAIGHT, 0 );
+            AppendCorner( xL, yT, STRAIGHT, 0 );
+            Close( STRAIGHT );
+        }
+#endif
+    }
+    return;
+}
+
+
+/** Function AddTrackWithClearancePolygon
+ * Add a polygon cutout for a track in a zone area
+ * Convert arcs and circles to multiple straight lines
+ */
+void AddTrackWithClearancePolygon( Bool_Engine* aBooleng,
+                                   TRACK& aTrack, int aClearanceValue )
+{
+    wxPoint corner_position;
+    int     ii, angle;
+    int     dx = (aTrack.m_Width / 2) + aClearanceValue;
+
+    int     delta = 3600 / s_CircleToSegmentsCount; // rot angle in 0.1 degree
+
+    switch( aTrack.Type() )
+    {
+    case TYPEVIA:
+        if( aBooleng->StartPolygonAdd( GROUP_B ) )
+        {
+            for( ii = 0; ii < s_CircleToSegmentsCount; ii++ )
+            {
+                corner_position = wxPoint( dx, 0 );
+                angle = ii * delta;
+                RotatePoint( &corner_position, angle );
+                corner_position += aTrack.m_Start;
+                aBooleng->AddPoint( corner_position.x, corner_position.y );
+            }
+
+            aBooleng->EndPolygonAdd();
+        }
+        break;
+
+    default:
+        AddRoundedEndsSegmentPolygon( aBooleng,
+                                     aTrack.m_Start, aTrack.m_End,
+                                     aTrack.m_Width + (2 * aClearanceValue) );
+        break;
+    }
+}
+
+
+/** Function AddRoundedEndsSegmentPolygon
+ * Add a polygon cutout for a segment (with rounded ends) in a zone area
+ * Convert arcs to multiple straight lines
+ */
+void AddRoundedEndsSegmentPolygon( Bool_Engine* aBooleng,
+                                   wxPoint aStart, wxPoint aEnd,
+                                   int aWidth )
+{
+    int     rayon  = aWidth / 2;
+    wxPoint endp   = aEnd - aStart; // end point coordinate for the same segment starting at (0,0)
+    wxPoint startp = aStart;
+    wxPoint corner;
+    int     seg_len;
+
+    // normalize the position in order to have endp.x >= 0;
+    if( endp.x < 0 )
+    {
+        endp   = aStart - aEnd;
+        startp = aEnd;
+    }
+    int delta_angle = ArcTangente( endp.y, endp.x );    // delta_angle is in 0.1 degrees
+    seg_len = (int) sqrt( (endp.y * endp.y) + (endp.x * endp.x) );
+
+    if( !aBooleng->StartPolygonAdd( GROUP_B ) )
+        return;                                 // error!
+
+    int delta = 3600 / s_CircleToSegmentsCount; // rot angle in 0.1 degree
+
+    // Compute the outlines of the segment, and creates a polygon
+    corner = wxPoint( 0, rayon );
+    RotatePoint( &corner, -delta_angle );
+    corner += startp;
+    aBooleng->AddPoint( corner.x, corner.y );
+
+    corner = wxPoint( seg_len, rayon );
+    RotatePoint( &corner, -delta_angle );
+    corner += startp;
+    aBooleng->AddPoint( corner.x, corner.y );
+
+    // add right rounded end:
+    for( int ii = delta; ii < 1800; ii += delta )
+    {
+        corner = wxPoint( 0, rayon );
+        RotatePoint( &corner, ii );
+        corner.x += seg_len;
+        RotatePoint( &corner, -delta_angle );
+        corner   += startp;
+        aBooleng->AddPoint( corner.x, corner.y );
+    }
+
+    corner = wxPoint( seg_len, -rayon );
+    RotatePoint( &corner, -delta_angle );
+    corner += startp;
+    aBooleng->AddPoint( corner.x, corner.y );
+
+    corner = wxPoint( 0, -rayon );
+    RotatePoint( &corner, -delta_angle );
+    corner += startp;
+    aBooleng->AddPoint( corner.x, corner.y );
+
+    // add left rounded end:
+    for( int ii = delta; ii < 1800; ii += delta )
+    {
+        corner = wxPoint( 0, -rayon );
+        RotatePoint( &corner, ii );
+        RotatePoint( &corner, -delta_angle );
+        corner   += startp;
+        aBooleng->AddPoint( corner.x, corner.y );
+    }
+    aBooleng->EndPolygonAdd();
+}

pcbnew/zones_non_copper_type_functions.cpp

@@ -166,19 +166,23 @@ void DialogNonCopperZonesEditor::OnCancelClick( wxCommandEvent& event )
 
 
 
-/***************************************************/
-int ZONE_CONTAINER::BuildFilledPolysListData( void )
-/***************************************************/
+/***********************************************************/
+int ZONE_CONTAINER::BuildFilledPolysListData( BOARD * aPcb )
+/***********************************************************/
 /** function BuildFilledPolysListData
  * Build m_FilledPolysList data from real outlines (m_Poly)
  * in order to have drawable (and plottable) filled polygons
  * drawable filled polygons are polygons without hole
+ * @param aPcb: the current board (can be NULL for non copper zones)
  * @return number of polygons
- * Currently useable only for non copper zones
+ * This function does not add holes for pads and tracks but calls
+ * AddClearanceAreasPolygonsToPolysList() to do that for copper layers
  */
 {
-    /* Currently only for non copper zones */
-    if ( IsOnCopperLayer() )
+
+    // Currently, for copper zones,  we can use segment filling or filling by polygon areas
+    // if m_GridFillValue == 0 polygon areas will be used (No Grid)
+    if ( IsOnCopperLayer() && ( m_GridFillValue != 0 ) )
         return 0;
 
     m_FilledPolysList.clear();
@@ -205,6 +209,13 @@ int ZONE_CONTAINER::BuildFilledPolysListData( void )
     }
 
     m_Poly->FreeKboolEngine();
+    
+    /* For copper layers, we now must add holes in the Polygon list.
+    holes are pads and tracks with their clearance area
+    */
+    
+    if ( IsOnCopperLayer() )
+        AddClearanceAreasPolygonsToPolysList( aPcb );
 
     return count;
 }

pcbnew/zones_test_and_combine_areas.cpp

@@ -343,7 +343,7 @@ int BOARD::AreaPolygonModified( ZONE_CONTAINER* modified_area,
         {
             for( unsigned ia = 0; ia < m_ZoneDescriptorList.size(); ia++ )
                 if( m_ZoneDescriptorList[ia]->GetLayer() == layer )
-                    m_ZoneDescriptorList[ia]->BuildFilledPolysListData( );
+                    m_ZoneDescriptorList[ia]->BuildFilledPolysListData( this );
         }
     }
     return test;

polygon/PolyLine.cpp

@@ -199,7 +199,7 @@ int CPolyLine::NormalizeWithKbool( std::vector<CPolyLine*> * aExtraPolyList, boo
 
 
 /** Function AddPolygonsToBoolEng
- * and edges contours to a kbool engine, preparing a boolean op between polygons
+ * Add a CPolyLine to a kbool engine, preparing a boolean op between polygons
  * @param aStart_contour: starting contour number (-1 = all, 0 is the outlines of zone, > 1 = holes in zone
  * @param aEnd_contour: ending contour number (-1 = all after  aStart_contour)
  * @param arc_array: arc converted to poly segments (NULL if not exists)
@@ -217,8 +217,10 @@ int CPolyLine::AddPolygonsToBoolEng( Bool_Engine*        aBooleng,
     if( (aGroup != GROUP_A) && (aGroup != GROUP_B ) )
         return 0; //Error !
 
+    /* Convert the current polyline contour to a kbool polygon: */
     MakeKboolPoly( aStart_contour, aEnd_contour, arc_array );
 
+    /* add the resulting kbool set of polygons to the current kcool engine */
     while( m_Kbool_Poly_Engine->StartPolygonGet() )
     {
         if( aBooleng->StartPolygonAdd( GROUP_A ) )