ci: add KiCad exports pipeline (ERC/DRC/PDF/BOM)

Auto-discovers .kicad_sch and .kicad_pcb files under hardware/ and
tools/. Runs ERC, DRC, exports PDF/SVG schematics, BOM and netlists.
Fails on ERC/DRC errors. Uploads artifacts.

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

.github/workflows/kicad-exports.yml

@@ -0,0 +1,308 @@
+name: KiCad Exports
+
+on:
+  push:
+    branches:
+      - main
+    paths:
+      - "hardware/**"
+      - "tools/hw/**"
+      - ".github/workflows/kicad-exports.yml"
+  pull_request:
+    paths:
+      - "hardware/**"
+      - "tools/hw/**"
+      - ".github/workflows/kicad-exports.yml"
+  workflow_dispatch:
+
+permissions:
+  contents: read
+
+concurrency:
+  group: ${{ github.workflow }}-${{ github.ref }}
+  cancel-in-progress: true
+
+env:
+  ARTIFACTS_DIR: artifacts/hw_exports
+
+jobs:
+  kicad-checks:
+    runs-on: ubuntu-latest
+    timeout-minutes: 20
+    steps:
+      - name: Checkout
+        uses: actions/checkout@v4
+
+      - name: Install KiCad 10
+        run: |
+          sudo add-apt-repository -y ppa:kicad/kicad-10.0-releases
+          sudo apt-get update
+          sudo apt-get install -y --no-install-recommends kicad
+          kicad-cli version
+
+      - name: Setup Python
+        uses: actions/setup-python@v5
+        with:
+          python-version: "3.11"
+
+      - name: Prepare output directories
+        run: |
+          mkdir -p "$ARTIFACTS_DIR/erc"
+          mkdir -p "$ARTIFACTS_DIR/drc"
+          mkdir -p "$ARTIFACTS_DIR/pdf"
+          mkdir -p "$ARTIFACTS_DIR/svg"
+          mkdir -p "$ARTIFACTS_DIR/bom"
+          mkdir -p "$ARTIFACTS_DIR/netlist"
+
+      # ── Discover all KiCad projects ──────────────────────────────
+      - name: Discover schematics and PCBs
+        id: discover
+        run: |
+          # Find all .kicad_pro files (each is a project root)
+          SCHEMATICS=$(find hardware -name "*.kicad_sch" \
+            -not -path "*/.kicad_blocks/*" \
+            -not -path "*/kicad_blocks/*" \
+            -not -path "*backup*" | sort)
+          PCBS=$(find hardware -name "*.kicad_pcb" | sort)
+
+          echo "Found schematics:"
+          echo "$SCHEMATICS"
+          echo ""
+          echo "Found PCBs:"
+          echo "${PCBS:-<none>}"
+
+          # Also check tools/cad proof fixtures
+          PROOF_PCBS=$(find tools/cad -name "*.kicad_pcb" 2>/dev/null | sort || true)
+          if [[ -n "$PROOF_PCBS" ]]; then
+            echo ""
+            echo "Found proof-fixture PCBs:"
+            echo "$PROOF_PCBS"
+            PCBS=$(printf "%s\n%s" "$PCBS" "$PROOF_PCBS" | sed '/^$/d')
+          fi
+
+          # Export for later steps
+          {
+            echo "schematics<<EOFSCH"
+            echo "$SCHEMATICS"
+            echo "EOFSCH"
+            echo "pcbs<<EOFPCB"
+            echo "$PCBS"
+            echo "EOFPCB"
+          } >> "$GITHUB_OUTPUT"
+
+      # ── ERC (Electrical Rules Check) ─────────────────────────────
+      - name: Run ERC on all schematics
+        id: erc
+        run: |
+          EXIT_CODE=0
+          while IFS= read -r SCH; do
+            [[ -z "$SCH" ]] && continue
+            BASENAME="$(basename "$SCH" .kicad_sch)"
+            echo "::group::ERC $SCH"
+            if kicad-cli sch erc "$SCH" \
+                --format json \
+                --output "$ARTIFACTS_DIR/erc/${BASENAME}_erc.json" 2>&1; then
+              # Parse error count
+              ERRORS=$(python3 -c "
+          import json, sys
+          try:
+              d = json.load(open('$ARTIFACTS_DIR/erc/${BASENAME}_erc.json'))
+              sheets = d.get('sheets', [])
+              errs = sum(1 for s in sheets for v in s.get('violations', []) if v.get('severity') == 'error')
+              print(errs)
+          except Exception as e:
+              print(f'parse-error: {e}', file=sys.stderr)
+              print(0)
+          ")
+              if [[ "$ERRORS" -gt 0 ]]; then
+                echo "::error file=$SCH::ERC found $ERRORS error(s)"
+                EXIT_CODE=1
+              else
+                echo "ERC passed: $SCH"
+              fi
+            else
+              echo "::warning file=$SCH::ERC command failed (kicad-cli error)"
+              EXIT_CODE=1
+            fi
+            echo "::endgroup::"
+          done <<< "${{ steps.discover.outputs.schematics }}"
+          echo "erc_exit=$EXIT_CODE" >> "$GITHUB_OUTPUT"
+
+      # ── DRC (Design Rules Check) ─────────────────────────────────
+      - name: Run DRC on all PCBs
+        id: drc
+        run: |
+          EXIT_CODE=0
+          while IFS= read -r PCB; do
+            [[ -z "$PCB" ]] && continue
+            BASENAME="$(basename "$PCB" .kicad_pcb)"
+            echo "::group::DRC $PCB"
+            if kicad-cli pcb drc "$PCB" \
+                --format json \
+                --output "$ARTIFACTS_DIR/drc/${BASENAME}_drc.json" 2>&1; then
+              ERRORS=$(python3 -c "
+          import json, sys
+          try:
+              d = json.load(open('$ARTIFACTS_DIR/drc/${BASENAME}_drc.json'))
+              errs = sum(1 for v in d.get('violations', []) if v.get('severity') == 'error')
+              print(errs)
+          except Exception as e:
+              print(f'parse-error: {e}', file=sys.stderr)
+              print(0)
+          ")
+              if [[ "$ERRORS" -gt 0 ]]; then
+                echo "::error file=$PCB::DRC found $ERRORS error(s)"
+                EXIT_CODE=1
+              else
+                echo "DRC passed: $PCB"
+              fi
+            else
+              echo "::warning file=$PCB::DRC command failed (kicad-cli error)"
+              EXIT_CODE=1
+            fi
+            echo "::endgroup::"
+          done <<< "${{ steps.discover.outputs.pcbs }}"
+          echo "drc_exit=$EXIT_CODE" >> "$GITHUB_OUTPUT"
+
+      # ── PDF Schematic Export ─────────────────────────────────────
+      - name: Export schematic PDFs
+        run: |
+          while IFS= read -r SCH; do
+            [[ -z "$SCH" ]] && continue
+            BASENAME="$(basename "$SCH" .kicad_sch)"
+            echo "Exporting PDF: $SCH"
+            kicad-cli sch export pdf "$SCH" \
+              --output "$ARTIFACTS_DIR/pdf/${BASENAME}.pdf" 2>&1 \
+              || echo "::warning file=$SCH::PDF export failed"
+          done <<< "${{ steps.discover.outputs.schematics }}"
+
+      # ── SVG Schematic Export ─────────────────────────────────────
+      - name: Export schematic SVGs
+        run: |
+          while IFS= read -r SCH; do
+            [[ -z "$SCH" ]] && continue
+            BASENAME="$(basename "$SCH" .kicad_sch)"
+            SVGDIR="$ARTIFACTS_DIR/svg/${BASENAME}"
+            mkdir -p "$SVGDIR"
+            echo "Exporting SVG: $SCH"
+            kicad-cli sch export svg "$SCH" \
+              --output "$SVGDIR/" 2>&1 \
+              || echo "::warning file=$SCH::SVG export failed"
+          done <<< "${{ steps.discover.outputs.schematics }}"
+
+      # ── BOM Export ───────────────────────────────────────────────
+      - name: Export BOMs
+        run: |
+          while IFS= read -r SCH; do
+            [[ -z "$SCH" ]] && continue
+            BASENAME="$(basename "$SCH" .kicad_sch)"
+            echo "Exporting BOM: $SCH"
+            kicad-cli sch export bom "$SCH" \
+              --output "$ARTIFACTS_DIR/bom/${BASENAME}_bom.csv" \
+              --fields 'Reference,Value,Footprint,Datasheet,Manufacturer,MPN,${QUANTITY},${DNP}' \
+              --group-by "Value" \
+              --sort-field "Reference" 2>&1 \
+              || echo "::warning file=$SCH::BOM export failed"
+          done <<< "${{ steps.discover.outputs.schematics }}"
+
+      # ── Netlist Export ───────────────────────────────────────────
+      - name: Export netlists
+        run: |
+          while IFS= read -r SCH; do
+            [[ -z "$SCH" ]] && continue
+            BASENAME="$(basename "$SCH" .kicad_sch)"
+            echo "Exporting netlist: $SCH"
+            kicad-cli sch export netlist "$SCH" \
+              --output "$ARTIFACTS_DIR/netlist/${BASENAME}_netlist.xml" 2>&1 \
+              || echo "::warning file=$SCH::Netlist export failed"
+          done <<< "${{ steps.discover.outputs.schematics }}"
+
+      # ── Summary ──────────────────────────────────────────────────
+      - name: Generate summary
+        if: always()
+        run: |
+          echo "## KiCad Export Summary" >> "$GITHUB_STEP_SUMMARY"
+          echo "" >> "$GITHUB_STEP_SUMMARY"
+
+          # ERC results
+          echo "### ERC Reports" >> "$GITHUB_STEP_SUMMARY"
+          for f in "$ARTIFACTS_DIR"/erc/*.json; do
+            [[ -f "$f" ]] || continue
+            NAME="$(basename "$f" _erc.json)"
+            ERRORS=$(python3 -c "
+          import json
+          d = json.load(open('$f'))
+          sheets = d.get('sheets', [])
+          errs = sum(1 for s in sheets for v in s.get('violations', []) if v.get('severity') == 'error')
+          warns = sum(1 for s in sheets for v in s.get('violations', []) if v.get('severity') == 'warning')
+          print(f'{errs} errors, {warns} warnings')
+          " 2>/dev/null || echo "parse error")
+            echo "- **$NAME**: $ERRORS" >> "$GITHUB_STEP_SUMMARY"
+          done
+
+          # DRC results
+          echo "" >> "$GITHUB_STEP_SUMMARY"
+          echo "### DRC Reports" >> "$GITHUB_STEP_SUMMARY"
+          for f in "$ARTIFACTS_DIR"/drc/*.json; do
+            [[ -f "$f" ]] || continue
+            NAME="$(basename "$f" _drc.json)"
+            ERRORS=$(python3 -c "
+          import json
+          d = json.load(open('$f'))
+          errs = sum(1 for v in d.get('violations', []) if v.get('severity') == 'error')
+          warns = sum(1 for v in d.get('violations', []) if v.get('severity') == 'warning')
+          print(f'{errs} errors, {warns} warnings')
+          " 2>/dev/null || echo "parse error")
+            echo "- **$NAME**: $ERRORS" >> "$GITHUB_STEP_SUMMARY"
+          done
+
+          # Exports
+          echo "" >> "$GITHUB_STEP_SUMMARY"
+          echo "### Exported Artifacts" >> "$GITHUB_STEP_SUMMARY"
+          echo "- PDFs: $(find "$ARTIFACTS_DIR/pdf" -name "*.pdf" 2>/dev/null | wc -l | tr -d ' ') files" >> "$GITHUB_STEP_SUMMARY"
+          echo "- SVGs: $(find "$ARTIFACTS_DIR/svg" -name "*.svg" 2>/dev/null | wc -l | tr -d ' ') files" >> "$GITHUB_STEP_SUMMARY"
+          echo "- BOMs: $(find "$ARTIFACTS_DIR/bom" -name "*.csv" 2>/dev/null | wc -l | tr -d ' ') files" >> "$GITHUB_STEP_SUMMARY"
+          echo "- Netlists: $(find "$ARTIFACTS_DIR/netlist" -name "*.xml" 2>/dev/null | wc -l | tr -d ' ') files" >> "$GITHUB_STEP_SUMMARY"
+
+      # ── Upload Artifacts ─────────────────────────────────────────
+      - name: Upload ERC/DRC reports
+        if: always()
+        uses: actions/upload-artifact@v4
+        with:
+          name: kicad-reports
+          if-no-files-found: warn
+          path: |
+            artifacts/hw_exports/erc/
+            artifacts/hw_exports/drc/
+
+      - name: Upload schematic exports
+        if: always()
+        uses: actions/upload-artifact@v4
+        with:
+          name: kicad-schematics
+          if-no-files-found: warn
+          path: |
+            artifacts/hw_exports/pdf/
+            artifacts/hw_exports/svg/
+
+      - name: Upload BOM and netlists
+        if: always()
+        uses: actions/upload-artifact@v4
+        with:
+          name: kicad-bom-netlist
+          if-no-files-found: warn
+          path: |
+            artifacts/hw_exports/bom/
+            artifacts/hw_exports/netlist/
+
+      # ── Fail if ERC or DRC had errors ────────────────────────────
+      - name: Check ERC/DRC results
+        if: always()
+        run: |
+          ERC_EXIT="${{ steps.erc.outputs.erc_exit }}"
+          DRC_EXIT="${{ steps.drc.outputs.drc_exit }}"
+          if [[ "${ERC_EXIT:-0}" -ne 0 ]] || [[ "${DRC_EXIT:-0}" -ne 0 ]]; then
+            echo "::error::ERC or DRC checks failed. Review the uploaded reports."
+            exit 1
+          fi
+          echo "All ERC/DRC checks passed."