Include the net's traces as conductors alongside zone fills

Straight tracks become capsule outline polygons (rectangle +
semicircular caps), arc tracks annular bands with end caps, both
tessellated to the same sagitta tolerance as zone-fill arcs; they merge
into the per-layer copper next to the fills, so rasterization, via
stitching, the solver and the plots handle them unchanged. Trace-only
layers and trace-only nets now qualify as candidates. Dialog checkbox
(on by default, INCLUDE_TRACKS) toggles them per run.

Hole-less polygons (every track outline) now paint the layer mask
directly instead of allocating a full-frame temporary each.

Tests: exact N-cell chain on a rasterized capsule, analytic annular-
sector convergence for an arc trace, capsule/arc-band outline geometry
invariants, collinear-arc degradation, and fill+trace union solve.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>

README.md

@@ -1,10 +1,10 @@
 # Fill Resistance — KiCad 10 plugin
 
-Computes the **DC or AC resistance of copper zone fills** between two
-contacts, **single- or multi-layer**: the chosen net's fills on the
-selected copper layers are solved as coupled finite-difference sheets
-linked by the net's **via and through-hole-pad barrels** (18 µm plating,
-configurable). At a user-set **frequency** the exact 1D foil/barrel
+Computes the **DC or AC resistance of copper zone fills and traces**
+between two contacts, **single- or multi-layer**: the chosen net's fills
+and tracks on the selected copper layers are solved as coupled
+finite-difference sheets linked by the net's **via and through-hole-pad
+barrels** (18 µm plating, configurable). At a user-set **frequency** the exact 1D foil/barrel
 skin-effect correction is applied (AC results are a rigorous lower
 bound — see *Model & limits*). Shows per-layer rasterized maps,
 potential, current density, and **power density**, reports **per-via
@@ -78,8 +78,10 @@ SWIG API. Requires KiCad **10.0.1+**.
   spokes** still connect; wider antipads do not, and the barrel bridges
   the layers above/below with the full barrel length. Barrels that reach
   fill on fewer than two layers carry no current and are reported.
-- Tracks and pad copper (other than the selected contacts) are **not**
-  part of the conductor model — zone fills + barrels only.
+- The net's **traces** (straight and arc tracks, exact outline polygons
+  incl. rounded ends) conduct together with the fills — dialog checkbox,
+  on by default (`INCLUDE_TRACKS`). Pad copper other than the selected
+  contacts is still **not** part of the conductor model.
 - **Solder buildup on mask openings** (dialog checkbox, **off by
   default**; `INCLUDE_MASK_BUILDUP`): zones drawn on `F.Mask`/`B.Mask`
   are treated as mask openings that collect `SOLDER_THICKNESS_UM`

fill_resistance/board_io.py

@@ -11,7 +11,7 @@ from pathlib import Path
 
 from kipy import KiCad
 from kipy.board import Board
-from kipy.board_types import BoardRectangle, Pad
+from kipy.board_types import ArcTrack, BoardRectangle, Pad
 from kipy.proto.board.board_pb2 import BoardStackupLayerType
 from kipy.proto.board.board_types_pb2 import ZoneType
 from kipy.util.board_layer import (canonical_name, is_copper_layer,
@@ -20,7 +20,8 @@ from kipy.util.board_layer import (canonical_name, is_copper_layer,
 from . import config
 from .errors import ApiVersionError, CandidateError, SelectionError
 from .geometry import (Electrode, LayerFill, Polygon, Problem, Rect,
-                       SurfaceBuildup, ViaLink, linearize_ring)
+                       SurfaceBuildup, ViaLink, arc_band_ring, capsule_ring,
+                       linearize_ring)
 
 MASK_TO_COPPER = {"F.Mask": "F.Cu", "B.Mask": "B.Cu"}
 
@@ -302,6 +303,39 @@ def gather_net_fills(board: Board) -> dict[str, dict[str, list[Polygon]]]:
     return fills
 
 
+def gather_net_tracks(board: Board) -> dict[str, dict[str, list[Polygon]]]:
+    """net -> layer -> track outline polygons (straight capsules and arc
+    bands). Traces conduct together with the zone fills."""
+    out: dict[str, dict[str, list[Polygon]]] = {}
+    for t in board.get_tracks():
+        if not is_copper_layer(t.layer):
+            continue
+        width = int(t.width or 0)
+        if width <= 0:
+            continue
+        if isinstance(t, ArcTrack):
+            ring = arc_band_ring((t.start.x, t.start.y), (t.mid.x, t.mid.y),
+                                 (t.end.x, t.end.y), width, ARC_TOL_NM)
+        else:
+            ring = capsule_ring(t.start.x, t.start.y, t.end.x, t.end.y,
+                                width, ARC_TOL_NM)
+        net = t.net.name if t.net is not None else "<no net>"
+        out.setdefault(net, {}).setdefault(
+            canonical_name(t.layer), []).append(Polygon(outline=ring))
+    return out
+
+
+def merge_copper(fills: dict, tracks: dict) -> dict:
+    """net -> layer -> fill + track polygons, for candidate detection
+    and the dialog's layer lists (build_problem merges the same way)."""
+    out: dict[str, dict[str, list[Polygon]]] = {}
+    for src in (fills, tracks):
+        for net, per_layer in src.items():
+            for layer, polys in per_layer.items():
+                out.setdefault(net, {}).setdefault(layer, []).extend(polys)
+    return out
+
+
 def _rect_overlaps(rect: Rect, polygons: list[Polygon]) -> bool:
     for p in polygons:
         px0, py0 = p.outline.min(axis=0)
@@ -413,15 +447,18 @@ def build_problem(board: Board, net: str, layer_names: list[str],
                   es1: list[Electrode], es2: list[Electrode],
                   stackup: StackupInfo, fills: dict,
                   buildups: dict[str, list[Polygon]] | None = None,
-                  extra_cu_um: float | None = None) -> Problem:
+                  extra_cu_um: float | None = None,
+                  tracks: dict | None = None) -> Problem:
     per_layer = fills.get(net, {})
+    per_layer_tracks = (tracks or {}).get(net, {})
     layers = []
     for name in stackup.names:                 # keep stackup order
         if name not in layer_names:
             continue
-        polys = per_layer.get(name, [])
+        polys = (list(per_layer.get(name, []))
+                 + list(per_layer_tracks.get(name, [])))
         if not polys:
-            print(f"note: net {net} has no fill on {name} - layer skipped")
+            print(f"note: net {net} has no copper on {name} - layer skipped")
             continue
         if config.COPPER_THICKNESS_UM is not None:
             t = int(config.COPPER_THICKNESS_UM * 1000)
@@ -440,9 +477,10 @@ def build_problem(board: Board, net: str, layer_names: list[str],
         SurfaceBuildup(layer_name=name, polygons=polys)
         for name, polys in (buildups or {}).items() if name in included
     ]
+    n_tracks = sum(len(per_layer_tracks.get(name, [])) for name in included)
     print(f"net {net}: {len(layers)} layer(s) "
           f"({', '.join(l.layer_name for l in layers)}), "
-          f"{len(vias)} via/pad barrel(s)"
+          f"{n_tracks} track(s), {len(vias)} via/pad barrel(s)"
           + (f", solder buildup on "
              f"{', '.join(b.layer_name for b in buildup_list)}"
              if buildup_list else ""))
@@ -477,7 +515,9 @@ if __name__ == "__main__":
     if any_zone_unfilled(board):
         refill(board)
     fills = gather_net_fills(board)
-    nets = nets_overlapping(fills, es1, es2)
+    tracks = gather_net_tracks(board) if config.INCLUDE_TRACKS else {}
+    copper = merge_copper(fills, tracks)
+    nets = nets_overlapping(copper, es1, es2)
     if len(sys.argv) > 2:
         net = sys.argv[2]
     elif net_hint in nets:
@@ -487,7 +527,7 @@ if __name__ == "__main__":
     else:
         print(f"candidate nets: {nets}; pass one as second argument")
         sys.exit(1)
-    problem = build_problem(board, net, list(fills.get(net, {})), es1, es2,
-                            stackup, fills)
+    problem = build_problem(board, net, list(copper.get(net, {})), es1, es2,
+                            stackup, fills, tracks=tracks)
     save_problem(problem, out)
     print(f"wrote {out}")

fill_resistance/config.py

@@ -39,6 +39,9 @@ BUILDUP_EXTRA_CU_UM = 0.0       # optional user-added copper (busbar/wire
                                 # soldered into the opening); dialog-settable
 
 # --- Zone / layer selection ---
+INCLUDE_TRACKS = True           # the net's traces (straight + arc tracks)
+                                # conduct together with the zone fills;
+                                # dialog-toggleable
 LAYER_HINT: str | None = None   # e.g. "F.Cu" to disambiguate candidate fills
 ELECTRODE_POS_LAYER = "User.1"  # rectangles on this layer mark V+ contact parts
 ELECTRODE_NEG_LAYER = "User.2"  # rectangles on this layer mark V- contact parts

fill_resistance/dialog.py

@@ -35,6 +35,7 @@ class Selection:
     contact_model: str = "uniform"
     include_buildup: bool = False
     extra_cu_um: float = 0.0
+    include_tracks: bool = True
 
 
 class _Dialog(QDialog):
@@ -59,6 +60,11 @@ class _Dialog(QDialog):
         self.layer_list.setMaximumHeight(120)
         form.addRow("Layers:", self.layer_list)
 
+        self.tracks_check = QCheckBox("include the net's traces "
+                                      "(tracks + arcs)")
+        self.tracks_check.setChecked(config.INCLUDE_TRACKS)
+        form.addRow("Conductors:", self.tracks_check)
+
         self.contact1_box = QComboBox()
         self.contact2_box = QComboBox()
         form.addRow(f"V+ ({e1_label}):", self.contact1_box)
@@ -199,7 +205,8 @@ class _Dialog(QDialog):
                          freq_hz=freq,
                          contact_model=self.model_box.currentData(),
                          include_buildup=self.buildup_check.isChecked(),
-                         extra_cu_um=extra_cu)
+                         extra_cu_um=extra_cu,
+                         include_tracks=self.tracks_check.isChecked())
 
     def _try_accept(self) -> None:
         try:

fill_resistance/geometry.py

@@ -132,10 +132,9 @@ class Problem:
         return int(xs.min()), int(ys.min()), int(xs.max()), int(ys.max())
 
 
-def arc_points(start, mid, end, tol_nm: float) -> np.ndarray:
-    """Tessellate a start/mid/end arc into points from start (inclusive)
-    to end (exclusive), max sagitta <= tol_nm. Collinear input degrades
-    to just the start point (straight segment)."""
+def _arc_params(start, mid, end) -> tuple[float, float, float, float, float] | None:
+    """Circle through three points: (cx, cy, r, a0, sweep) with a0 the
+    start angle and sweep signed; None if the points are collinear."""
     sx, sy = float(start[0]), float(start[1])
     mx, my = float(mid[0]), float(mid[1])
     ex, ey = float(end[0]), float(end[1])
@@ -143,30 +142,109 @@ def arc_points(start, mid, end, tol_nm: float) -> np.ndarray:
     d = 2.0 * (sx * (my - ey) + mx * (ey - sy) + ex * (sy - my))
     chord = math.hypot(ex - sx, ey - sy)
     if abs(d) < 1e-9 * max(chord, 1.0):
-        return np.array([[start[0], start[1]]], dtype=np.int64)
-    ux = ((sx**2 + sy**2) * (my - ey) + (mx**2 + my**2) * (ey - sy)
+        return None
+    cx = ((sx**2 + sy**2) * (my - ey) + (mx**2 + my**2) * (ey - sy)
           + (ex**2 + ey**2) * (sy - my)) / d
-    uy = ((sx**2 + sy**2) * (ex - mx) + (mx**2 + my**2) * (sx - ex)
+    cy = ((sx**2 + sy**2) * (ex - mx) + (mx**2 + my**2) * (sx - ex)
           + (ex**2 + ey**2) * (mx - sx)) / d
-    r = math.hypot(sx - ux, sy - uy)
+    r = math.hypot(sx - cx, sy - cy)
 
-    a0 = math.atan2(sy - uy, sx - ux)
-    a1 = math.atan2(my - uy, mx - ux)
-    a2 = math.atan2(ey - uy, ex - ux)
+    a0 = math.atan2(sy - cy, sx - cx)
+    a1 = math.atan2(my - cy, mx - cx)
+    a2 = math.atan2(ey - cy, ex - cx)
     two_pi = 2.0 * math.pi
     d01 = (a1 - a0) % two_pi
     d02 = (a2 - a0) % two_pi
     sweep = d02 if d01 <= d02 else d02 - two_pi
+    return cx, cy, r, a0, sweep
 
+
+def _n_arc_segments(sweep_abs: float, r: float, tol_nm: float) -> int:
+    """Segments needed to keep the sagitta of each chord <= tol_nm."""
     tol = min(tol_nm, 0.999 * r)
     dtheta_max = 2.0 * math.acos(1.0 - tol / r)
-    n = max(2, int(math.ceil(abs(sweep) / dtheta_max)))
+    return max(2, int(math.ceil(sweep_abs / dtheta_max)))
+
+
+def arc_points(start, mid, end, tol_nm: float) -> np.ndarray:
+    """Tessellate a start/mid/end arc into points from start (inclusive)
+    to end (exclusive), max sagitta <= tol_nm. Collinear input degrades
+    to just the start point (straight segment)."""
+    params = _arc_params(start, mid, end)
+    if params is None:
+        return np.array([[start[0], start[1]]], dtype=np.int64)
+    cx, cy, r, a0, sweep = params
+    n = _n_arc_segments(abs(sweep), r, tol_nm)
     ks = np.arange(n)
     angs = a0 + sweep * ks / n
-    pts = np.stack([ux + r * np.cos(angs), uy + r * np.sin(angs)], axis=1)
+    pts = np.stack([cx + r * np.cos(angs), cy + r * np.sin(angs)], axis=1)
     return np.round(pts).astype(np.int64)
 
 
+def capsule_ring(x1: int, y1: int, x2: int, y2: int, width_nm: int,
+                 tol_nm: float) -> np.ndarray:
+    """Outline (open ring, int64 nm) of a straight track segment: a
+    rectangle with semicircular end caps; a circle for a zero-length
+    segment. Cap sagitta <= tol_nm."""
+    r = width_nm / 2.0
+    dx, dy = float(x2 - x1), float(y2 - y1)
+    length = math.hypot(dx, dy)
+    n = _n_arc_segments(math.pi, r, tol_nm)
+    if length < 1.0:
+        angs = np.linspace(0.0, 2.0 * math.pi, 2 * n, endpoint=False)
+        pts = np.stack([x1 + r * np.cos(angs), y1 + r * np.sin(angs)],
+                       axis=1)
+        return np.round(pts).astype(np.int64)
+    ux, uy = dx / length, dy / length
+    a0 = math.atan2(ux, -uy)                  # angle of the left normal
+    ks = np.arange(n + 1)
+    cap2 = a0 - ks * math.pi / n              # +normal -> -normal, around end
+    cap1 = a0 - (ks + n) * math.pi / n        # -normal -> +normal, around start
+    pts = np.concatenate([
+        np.stack([x2 + r * np.cos(cap2), y2 + r * np.sin(cap2)], axis=1),
+        np.stack([x1 + r * np.cos(cap1), y1 + r * np.sin(cap1)], axis=1),
+    ])
+    return np.round(pts).astype(np.int64)
+
+
+def arc_band_ring(start, mid, end, width_nm: int, tol_nm: float) -> np.ndarray:
+    """Outline of an arc track: the annular band of the given width
+    around the start/mid/end centerline, with semicircular end caps.
+    Collinear input degrades to the straight capsule."""
+    params = _arc_params(start, mid, end)
+    if params is None:
+        return capsule_ring(start[0], start[1], end[0], end[1], width_nm,
+                            tol_nm)
+    cx, cy, r, a0, sweep = params
+    w2 = width_nm / 2.0
+    router = r + w2
+    rinner = max(r - w2, 0.0)
+    sgn = 1.0 if sweep >= 0 else -1.0
+    a1 = a0 + sweep
+    m = _n_arc_segments(abs(sweep), router, tol_nm)
+    ncap = _n_arc_segments(math.pi, w2, tol_nm)
+    ks = np.arange(m + 1)
+
+    th = a0 + sweep * ks / m                  # outer arc, start -> end
+    parts = [np.stack([cx + router * np.cos(th),
+                       cy + router * np.sin(th)], axis=1)]
+    ex_, ey_ = cx + r * math.cos(a1), cy + r * math.sin(a1)
+    ca = a1 + sgn * math.pi * np.arange(1, ncap) / ncap   # end cap, bulges
+    parts.append(np.stack([ex_ + w2 * np.cos(ca),        # along exit tangent
+                           ey_ + w2 * np.sin(ca)], axis=1))
+    if rinner > 0:
+        th = a1 - sweep * ks / m              # inner arc, end -> start
+        parts.append(np.stack([cx + rinner * np.cos(th),
+                               cy + rinner * np.sin(th)], axis=1))
+    else:
+        parts.append(np.array([[cx, cy]]))    # band swallows the center
+    sx_, sy_ = cx + r * math.cos(a0), cy + r * math.sin(a0)
+    ca = a0 + math.pi + sgn * math.pi * np.arange(1, ncap) / ncap
+    parts.append(np.stack([sx_ + w2 * np.cos(ca),        # start cap, bulges
+                           sy_ + w2 * np.sin(ca)], axis=1))  # backwards
+    return np.round(np.concatenate(parts)).astype(np.int64)
+
+
 def linearize_ring(nodes: list, tol_nm: float) -> np.ndarray:
     """nodes: list of ('pt', (x, y)) or ('arc', (start, mid, end)) tuples,
     already in board nm. Returns an (N, 2) int64 open ring."""

fill_resistance/main.py

@@ -37,7 +37,9 @@ def main() -> None:
             if board_io.any_zone_unfilled(board) or config.ALWAYS_REFILL:
                 board_io.refill(board)
             fills = board_io.gather_net_fills(board)
-            candidate_nets = board_io.nets_overlapping(fills, es1, es2)
+            tracks = board_io.gather_net_tracks(board)
+            copper = board_io.merge_copper(fills, tracks)
+            candidate_nets = board_io.nets_overlapping(copper, es1, es2)
             buildups = board_io.gather_mask_buildups(board)
         except ApiError as e:
             raise UserFacingError(
@@ -47,9 +49,9 @@ def main() -> None:
 
         if not candidate_nets:
             raise CandidateError(
-                "No copper zone fill overlaps both contacts. Check that both "
-                "sit over (or in) filled pours and that the fills are up to "
-                "date (press B in the board editor)."
+                "No copper (zone fill or trace) overlaps both contacts. "
+                "Check that both sit over copper of the same net and that "
+                "the fills are up to date (press B in the board editor)."
             )
 
         def group_label(parts):
@@ -64,7 +66,7 @@ def main() -> None:
         default_net = (net_hint if net_hint in candidate_nets
                        else candidate_nets[0])
         selection = dialog.ask(
-            candidates={n: list(fills[n].keys()) for n in candidate_nets},
+            candidates={n: list(copper[n].keys()) for n in candidate_nets},
             layer_order=stackup.names,
             default_net=default_net,
             e1_label=group_label(es1), e2_label=group_label(es2),
@@ -89,7 +91,8 @@ def main() -> None:
                 board, selection.net, selection.layers, es1, es2, stackup,
                 fills,
                 buildups=(buildups if selection.include_buildup else None),
-                extra_cu_um=selection.extra_cu_um)
+                extra_cu_um=selection.extra_cu_um,
+                tracks=(tracks if selection.include_tracks else None))
             outdir = report.make_output_dir(board_io.board_dir(board))
         except ApiError as e:
             raise UserFacingError(f"KiCad API error: {e}")

fill_resistance/raster.py

@@ -167,11 +167,16 @@ def rasterize_stack(problem: Problem, h_nm: float) -> RasterStack:
     )
     for li, layer in enumerate(problem.layers):
         for poly in layer.polygons:
+            if poly.holes:
                 pmask = np.zeros((ny, nx), dtype=bool)
                 _paint_ring(stack, poly.outline, True, pmask)
                 for hole in poly.holes:
                     _paint_ring(stack, hole, False, pmask)
                 stack.masks[li] |= pmask
+            else:
+                # hole-less (e.g. one of many track outlines): paint the
+                # layer mask directly, skipping the full-frame temp
+                _paint_ring(stack, poly.outline, True, stack.masks[li])
 
     if problem.buildups:
         stack.buildup = np.zeros_like(stack.masks)

metadata.json

@@ -1,8 +1,8 @@
 {
     "$schema": "https://go.kicad.org/pcm/schemas/v2",
     "name": "Fill Resistance",
-    "description": "DC/AC resistance of copper zone fills between two contacts, single- or multi-layer with via coupling, with current and power density maps.",
-    "description_full": "Computes the DC or AC resistance of copper zone fills between two contacts (marker rectangles on User.1/User.2 and/or selected pads), single- or multi-layer: the chosen net's fills are solved as coupled finite-difference sheets linked by the net's via and through-hole-pad barrels.\n\nShows per-layer rasterized maps, potential, current density and power density, reports per-via currents (via ampacity) and total dissipation at a selectable test current. At a user-set frequency the exact 1D foil/barrel skin-effect correction is applied (AC results are a rigorous lower bound). PNGs, a text summary and a re-solvable geometry dump are saved per run.\n\nNote: the first load builds the plugin's Python environment (numpy, scipy, pyamg, matplotlib, PySide6) and can take several minutes.",
+    "description": "DC/AC resistance of copper zone fills and traces between two contacts, single- or multi-layer with via coupling; current and power density maps.",
+    "description_full": "Computes the DC or AC resistance of copper zone fills and traces between two contacts (marker rectangles on User.1/User.2 and/or selected pads), single- or multi-layer: the chosen net's fills and tracks are solved as coupled finite-difference sheets linked by the net's via and through-hole-pad barrels.\n\nShows per-layer rasterized maps, potential, current density and power density, reports per-via currents (via ampacity) and total dissipation at a selectable test current. At a user-set frequency the exact 1D foil/barrel skin-effect correction is applied (AC results are a rigorous lower bound). PNGs, a text summary and a re-solvable geometry dump are saved per run.\n\nNote: the first load builds the plugin's Python environment (numpy, scipy, pyamg, matplotlib, PySide6) and can take several minutes.",
     "identifier": "th.co.b4l.fill-resistance",
     "type": "plugin",
     "author": {

plugin.json

@@ -2,7 +2,7 @@
     "$schema": "https://go.kicad.org/api/schemas/v1",
     "identifier": "th.co.b4l.fill-resistance",
     "name": "Fill Resistance",
-    "description": "DC/AC resistance of copper zone fills between two contacts (marker rectangles or pads), single- or multi-layer with via coupling",
+    "description": "DC/AC resistance of copper zone fills and traces between two contacts (marker rectangles or pads), single- or multi-layer with via coupling",
     "runtime": {
         "type": "python"
     },

tests/test_tracks.py

@@ -0,0 +1,145 @@
+"""Track (trace) conductor tests: capsule / arc-band outline generation
+and solves on rasterized traces. The 1-cell-wide capsule chain is exact;
+the arc band is checked against the analytic annular-sector resistance."""
+import math
+
+import numpy as np
+import pytest
+
+from fill_resistance import raster, solver
+from fill_resistance.geometry import (Electrode, LayerFill, Polygon, Problem,
+                                      arc_band_ring, capsule_ring)
+from tests.util import NM, rect_mm, sigma_s
+
+TOL_NM = 10_000
+
+
+def _track_problem(rings, rect1, rect2, t_um=70.0):
+    return Problem(
+        board_path="synthetic", net_name="TEST", rho_ohm_m=1.68e-8,
+        plating_nm=18_000,
+        layers=[LayerFill(layer_name="F.Cu", thickness_nm=int(t_um * 1000),
+                          z_nm=0,
+                          polygons=[Polygon(outline=r) for r in rings])],
+        vias=[],
+        electrodes1=[Electrode(rect=rect_mm(rect1))],
+        electrodes2=[Electrode(rect=rect_mm(rect2))],
+    )
+
+
+def _solve(problem, h_mm):
+    stack = raster.rasterize_stack(problem, h_mm * NM)
+    e1, e2 = raster.electrode_masks(stack, problem)
+    return solver.run_solve(problem, stack, e1, e2, 1.0,
+                            contact_model="equipotential"), stack
+
+
+def test_straight_track_exact_chain():
+    """A 1.2 mm wide capsule at h = 1 mm rasterizes to a single-cell-high
+    row (the grid origin floats with the polygon bbox, so the count is
+    taken from the mask): an N-cell chain solves to exactly (N-1) faces."""
+    ring = capsule_ring(1 * NM, NM // 2, 9 * NM, NM // 2,
+                        int(1.2 * NM), TOL_NM)
+    p = _track_problem([ring], (0, 0, 1.5, 1), (8.5, 0, 10, 1))
+    res, stack = _solve(p, 1.0)
+    m = stack.masks[0]
+    rows = np.flatnonzero(m.any(axis=1))
+    assert len(rows) == 1                     # one 1-cell-high chain
+    n = int(m.sum())
+    assert n >= 8
+    assert res.R_ohm == pytest.approx((n - 1) / sigma_s(), rel=1e-9)
+
+
+def test_capsule_zero_length_is_circle():
+    ring = capsule_ring(5 * NM, 5 * NM, 5 * NM, 5 * NM, 2 * NM, TOL_NM)
+    d = np.hypot(ring[:, 0] - 5 * NM, ring[:, 1] - 5 * NM)
+    assert np.allclose(d, NM, atol=TOL_NM + 2)
+    assert len(ring) >= 8
+
+
+def test_capsule_ring_geometry():
+    """Every outline point lies on the capsule boundary: at half-width
+    from the centerline segment."""
+    ring = capsule_ring(2 * NM, 3 * NM, 17 * NM, 11 * NM,
+                        int(1.5 * NM), TOL_NM)
+    a = np.array([2 * NM, 3 * NM], dtype=float)
+    b = np.array([17 * NM, 11 * NM], dtype=float)
+    ab = b - a
+    t = np.clip(((ring - a) @ ab) / (ab @ ab), 0.0, 1.0)
+    d = np.hypot(*(ring - (a + t[:, None] * ab)).T)
+    assert np.allclose(d, 0.75 * NM, atol=TOL_NM + 2)
+
+
+def test_arc_band_ring_geometry():
+    """Arc-band points lie on the annulus walls or on the end caps."""
+    start, mid, end = ((10 * NM, 0), (int(10 * NM / math.sqrt(2)),
+                                      int(10 * NM / math.sqrt(2))),
+                      (0, 10 * NM))
+    ring = arc_band_ring(start, mid, end, 1 * NM, TOL_NM).astype(float)
+    r = np.hypot(ring[:, 0], ring[:, 1])
+    on_annulus = (np.abs(r - 10.5 * NM) < TOL_NM + 2) \
+        | (np.abs(r - 9.5 * NM) < TOL_NM + 2)
+    d_start = np.hypot(ring[:, 0] - start[0], ring[:, 1] - start[1])
+    d_end = np.hypot(ring[:, 0] - end[0], ring[:, 1] - end[1])
+    on_caps = (d_start < 0.5 * NM + TOL_NM + 2) | (d_end < 0.5 * NM + TOL_NM + 2)
+    assert (on_annulus | on_caps).all()
+
+
+def test_collinear_arc_degrades_to_capsule():
+    cap = capsule_ring(0, 0, 10 * NM, 0, NM, TOL_NM)
+    band = arc_band_ring((0, 0), (5 * NM, 0), (10 * NM, 0), NM, TOL_NM)
+    assert np.array_equal(cap, band)
+
+
+def test_arc_track_matches_annular_sector():
+    """90 deg arc trace, r = 10 mm, w = 1 mm: R = theta / (sigma *
+    ln(r_out/r_in)) between the radial end faces (electrodes cover the
+    end caps). The staircase on the curved walls narrows the band, so R
+    converges to the analytic value from above as h shrinks."""
+    start = (10 * NM, 0)
+    mid = (int(round(10 * NM / math.sqrt(2))),
+           int(round(10 * NM / math.sqrt(2))))
+    end = (0, 10 * NM)
+    ring = arc_band_ring(start, mid, end, 1 * NM, TOL_NM)
+
+    def solve_at(h_mm):
+        p = _track_problem([ring], rect1=(9.3, -0.8, 10.7, 0.05),
+                           rect2=(-0.8, 9.3, 0.05, 10.7))
+        res, _ = _solve(p, h_mm)
+        return res.R_ohm
+
+    r_exact = (math.pi / 2) / (sigma_s() * math.log(10.5 / 9.5))
+    err_coarse = abs(solve_at(0.1) / r_exact - 1)
+    err_fine = abs(solve_at(0.05) / r_exact - 1)
+    assert err_fine < err_coarse            # converges toward analytic
+    assert err_fine < 0.04
+
+
+def test_track_unions_with_fill():
+    """A trace overlapping a plate merges into one conductor: the mask is
+    the union, and R drops when the trace bridges a slot."""
+    plate = [(0, 0), (20, 0), (20, 10), (0, 10)]
+    slot = [(9, 2), (11, 2), (11, 10), (9, 10)]     # slot open to the top
+    plate_poly = Polygon(
+        outline=np.array([(x * NM, y * NM) for x, y in plate]),
+        holes=[np.array([(x * NM, y * NM) for x, y in slot])])
+    bridge = capsule_ring(6 * NM, 6 * NM, 14 * NM, 6 * NM,
+                          int(1.2 * NM), TOL_NM)
+
+    def problem(polys):
+        return Problem(
+            board_path="synthetic", net_name="TEST", rho_ohm_m=1.68e-8,
+            plating_nm=18_000,
+            layers=[LayerFill(layer_name="F.Cu", thickness_nm=70_000,
+                              z_nm=0, polygons=polys)],
+            vias=[],
+            electrodes1=[Electrode(rect=rect_mm((0, 0, 1, 10)))],
+            electrodes2=[Electrode(rect=rect_mm((19, 0, 20, 10)))],
+        )
+
+    r_plate, s_plate = _solve(problem([plate_poly]), 0.25)
+    r_both, s_both = _solve(problem([plate_poly,
+                                     Polygon(outline=bridge)]), 0.25)
+    assert int(s_both.masks.sum()) > int(s_plate.masks.sum())
+    assert r_both.R_ohm < 0.75 * r_plate.R_ohm    # bridge shortens the detour
+    assert r_both.power_balance_rel < 1e-9