Model every THT pad hole: exact pad copper, lead conductor, DNP holes
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- THT pad copper is now part of the conductor: the exact pad outline
  (incl. oblong/custom shapes) is fetched from KiCad once per pad and
  stamped onto every included layer (the outer shape stands in for
  inner rings). Annular rings bridge antipads, and joints land on real
  copper instead of only pour coverage.
- The internal lead conductor is modeled in every solder-filled hole:
  a cylinder of drill - THT_LEAD_CLEARANCE_MM (0.25 fab rule) with
  THT_LEAD_RHO_OHM_M (copper default; config for brass/steel leads),
  in parallel with the solder annulus and the plating.
- Drill mouths of THT pads: populated pads keep conducting mouth
  copper (stands in for the solder plug - conservative, the plug is
  worth ~200 um of copper equivalent); DNP pad holes are cut open on
  every layer like uncapped via mouths.
- Oblong pads: the coat uses the exact pad shape; the lead cone tapers
  within the inscribed circle (new pad_min_nm on ViaLink/Electrode) so
  the long axis is not overstated sideways.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
This commit is contained in:
janik
2026-07-16 19:15:57 +07:00
parent 38b6e34bfa
commit 959446978c
8 changed files with 217 additions and 56 deletions
+21 -13
View File
@@ -87,17 +87,24 @@ SWIG API. Requires KiCad **10.0.1+**.
fraction (4×4 supersampling), so coarse grids see the correct small
perturbation instead of a whole-cell hole. Barrels are gathered in
**single-layer runs too** (drill mouths perforate a lone plane).
THT-pad copper and drills remain outside the model, but every
**populated THT pad** of the net carries its full **soldered
joint** on its SOLDER side (opposite the component; the
component-side pad face stays bare): a solder-filled barrel (SAC305
core in parallel with the plating), the average-thickness solder
coat over a pad-diameter disc, and the protruding-lead cone (see
barrel contacts below). Whether a hole
is a via or a THT pad, the owning footprint's side, and its **Do not
populate** flag are all read from KiCad — DNP pads stay plating-only
with no joint. At f > 0 the thickness scaling is applied
multiplicatively to the skin-corrected sheet conductance
**THT pads are fully modeled**: their exact copper shapes (incl.
oblong pads, fetched from KiCad; the outer shape stands in for inner
rings) are stamped onto every included layer, and every **populated**
pad carries its full **soldered joint** on its SOLDER side (opposite
the component; the component-side pad face stays bare): the hole
holds the **component lead** (a cylinder of drill
`THT_LEAD_CLEARANCE_MM`, resistivity `THT_LEAD_RHO_OHM_M`, copper by
default — raise it for brass/steel leads) **plus solder** in the
remaining annulus, both in parallel with the plating; the mouth
copper stays conducting (it stands in for the plug — conservative,
the plug is worth far more than the foil); the pad face gets the
average-thickness solder coat (exact pad shape) and the
protruding-lead cone (see barrel contacts below; on oblong pads the
cone tapers within the inscribed circle). Whether a hole is a via or
a THT pad, the owning footprint's side, and its **Do not populate**
flag are all read from KiCad — **DNP pads** get an **open hole** and
a plating-only barrel, no joint. At f > 0 the thickness scaling is
applied multiplicatively to the skin-corrected sheet conductance
(approximation). Per layer a barrel attaches to
the fill cell under it, or to the nearest copper cell within the pad
footprint plus one grid cell — fills joined by **thermal-relief
@@ -112,8 +119,9 @@ SWIG API. Requires KiCad **10.0.1+**.
series resistance carries no discretization error and no cell-size
tuning is needed for thin traces. 1D-modeled traces show potential,
power density, and |J| (the true in-trace density from the link
currents, |ΔV|/(ρ·Δl)). Pad copper other than the selected
contacts is still **not** part of the conductor model.
currents, |ΔV|/(ρ·Δl)). THT pad copper is part of the conductor
(exact shapes, see above); **SMD** pad copper other than the
selected contacts is still **not**.
- **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`