Update bcf hardware inventory and gerber audit#27
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Two PCBA orders (12291944A-Y4, Y2) cancelled by JLCPCB QA due to missing F_Mask and B_Mask layers in initial gerber export from KiCad after Altium import. Fixed: - Re-exported all gerbers with solder mask and edge cuts layers - Verified F_Mask, B_Mask, Edge_Cuts present in all 4 zips - Archived corrected gerbers at assets/gerbers/opennirscap-v2/ - Documented incident and lesson learned in bcf-0036.tree PCBs: Uncut Gem (ECU), fNIRS ECU, sensor module, ST-LINK breakout
Every gerber file for all 4 boards listed with old status (MISSING/present) vs new filename and size. Signal paths documented from actual schematics. Sensor module and ST-LINK layers verified — all mask layers present.
Per-layer manufacturing requirements: mask polarity, expansion, outline closure, drill units/alignment/aspect ratio, trace width/spacing, copper balance, silk clearance, paste apertures. Based on IPC Class 2 and JLCPCB capability limits. Skill: pcb-design-verification.
- Cleaned 138 corrupt zones from Altium import (93 F.SilkS + 45 unnetted) - Filled 40 valid zones via pcbnew ZONE_FILLER - Re-exported gerbers via kicad-cli: 34 G36 regions across F_Cu/B_Cu/In1_Cu - ecu_gerbers_refilled.zip (530KB) replaces unfilled ecu_gerbers.zip (162KB) - In2_Cu has no zone definitions (Altium import limitation, documented) - Moved 4 skill-trees to trees/, added skill-trees to forest.toml Co-authored-by: factory-droid[bot] <138933559+factory-droid[bot]@users.noreply.github.com>
ECU Edge_Cuts: added 4 corner arcs (5mm radius) closing ~7mm gaps at each corner of the 112x112mm board outline. Sensor Module Edge_Cuts: split full-circle arc into two half-circle gr_arc primitives to work around KiCad 9.0.2 exporter bug where start==end arcs produce empty gerber output. Both boards verified: ECU has 4 G01 + 4 G02 commands, Sensor Module has 4 G02 arc commands forming complete circle outline. Co-authored-by: factory-droid[bot] <138933559+factory-droid[bot]@users.noreply.github.com>
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Summary
Verification