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Diffstat (limited to 'gerbolyze.py')
| -rwxr-xr-x | gerbolyze.py | 411 |
1 files changed, 411 insertions, 0 deletions
diff --git a/gerbolyze.py b/gerbolyze.py new file mode 100755 index 0000000..9f79a52 --- /dev/null +++ b/gerbolyze.py @@ -0,0 +1,411 @@ +#!/usr/bin/env python3 + +import subprocess +import zipfile +import tempfile +import os.path as path +import os +import sys +import time +import shutil +import math + +import tqdm +import gerber +from gerber.render import GerberCairoContext +import numpy as np +import cv2 +import enum + +class Unit(enum.Enum): + MM = 0 + INCH = 1 + MIL = 2 + + +def generate_mask( + outline, + target, + scale, + debugimg, + status_print, + gerber_unit, + extend_overlay_r_mil, + subtract_gerber + ): + # Render all gerber layers whose features are to be excluded from the target image, such as board outline, the + # original silk layer and the solder paste layer to binary images. + with tempfile.TemporaryDirectory() as tmpdir: + img_file = path.join(tmpdir, 'target.png') + + status_print('Combining keepout composite') + fg, bg = gerber.render.RenderSettings((1, 1, 1)), gerber.render.RenderSettings((0, 0, 0)) + ctx = GerberCairoContext(scale=scale) + status_print(' * outline') + ctx.render_layer(outline, settings=fg, bgsettings=bg) + status_print(' * target layer') + ctx.render_layer(target, settings=fg, bgsettings=bg) + for fn, sub in subtract_gerber: + status_print(' * extra layer', os.path.basename(fn)) + layer = gerber.loads(sub) + ctx.render_layer(layer, settings=fg, bgsettings=bg) + status_print('Rendering keepout composite') + ctx.dump(img_file) + + # Vertically flip exported image + original_img = cv2.imread(img_file, cv2.IMREAD_GRAYSCALE)[::-1, :] + + f = 1 if gerber_unit == Unit.INCH else 25.4 # MM + r = 1+2*max(1, int(extend_overlay_r_mil/1000 * f * scale)) + status_print('Expanding keepout composite by', r) + + # Extend image by a few pixels and flood-fill from (0, 0) to mask out the area outside the outermost outline + # This ensures no polygons are generated outside the board even for non-rectangular boards. + border = 10 + outh, outw = original_img.shape + extended_img = np.zeros((outh + 2*border, outw + 2*border), dtype=np.uint8) + extended_img[border:outh+border, border:outw+border] = original_img + cv2.floodFill(extended_img, None, (0, 0), (255,)) + original_img = extended_img[border:outh+border, border:outw+border] + debugimg(extended_img, 'flooded') + + # Dilate the white areas of the image using gaussian blur and threshold. Use these instead of primitive dilation + # here for their non-directionality. + target_img = cv2.blur(original_img, (r, r)) + _, target_img = cv2.threshold(target_img, 255//(1+r), 255, cv2.THRESH_BINARY) + return target_img + +def render_gerbers_to_image(*gerbers, scale, bounds=None): + with tempfile.TemporaryDirectory() as tmpdir: + img_file = path.join(tmpdir, 'target.png') + fg, bg = gerber.render.RenderSettings((1, 1, 1)), gerber.render.RenderSettings((0, 0, 0)) + ctx = GerberCairoContext(scale=scale) + + for grb in gerbers: + ctx.render_layer(grb, settings=fg, bgsettings=bg, bounds=bounds) + + ctx.dump(img_file) + # Vertically flip exported image to align coordinate systems + return cv2.imread(img_file, cv2.IMREAD_GRAYSCALE)[::-1, :] + +def pcb_area_mask(outline, scale): + # Merge layers to target mask + img = render_gerbers_to_image(outline, scale=scale) + # Extend + imgh, imgw = img.shape + img_ext = np.zeros(shape=(imgh+2, imgw+2), dtype=np.uint8) + img_ext[1:-1, 1:-1] = img + # Binarize + img_ext[img_ext < 128] = 0 + img_ext[img_ext >= 128] = 255 + # Flood-fill + cv2.floodFill(img_ext, None, (0, 0), (255,)) # Flood-fill with white from top left corner (0,0) + img_ext_snap = img_ext.copy() + cv2.floodFill(img_ext, None, (0, 0), (0,)) # Flood-fill with black + cv2.floodFill(img_ext, None, (0, 0), (255,)) # Flood-fill with white + return np.logical_xor(img_ext_snap, img_ext)[1:-1, 1:-1].astype(float) + +def generate_template( + silk, mask, copper, outline, drill, + image, + gerber_unit=Unit.MM, + process_resolution:float=6, # mil + resolution_oversampling:float=10, # times + status_print=lambda *args:None + ): + + silk, mask, copper, outline, *drill = map(gerber.load_layer_data, [silk, mask, copper, outline, *drill]) + silk.layer_class = 'topsilk' + mask.layer_class = 'topmask' + copper.layer_class = 'top' + outline.layer_class = 'outline' + scale = (1000/process_resolution) / 25.4 * resolution_oversampling # dpmm + + # Create a new drawing context + ctx = GerberCairoContext(scale=scale) + + ctx.render_layer(copper) + ctx.render_layer(mask) + ctx.render_layer(silk) + for dr in drill: + ctx.render_layer(dr) + ctx.dump(image) + +def paste_image( + target_gerber:str, + outline_gerber:str, + source_img:np.ndarray, + subtract_gerber:list=[], + extend_overlay_r_mil:float=6, + extend_picture_r_mil:float=2, + status_print=lambda *args:None, + gerber_unit=Unit.MM, + debugdir:str=None): + + debugctr = 0 + def debugimg(img, name): + nonlocal debugctr + if debugdir: + cv2.imwrite(path.join(debugdir, '{:02d}{}.png'.format(debugctr, name)), img) + debugctr += 1 + + # Parse outline layer to get bounds of gerber file + status_print('Parsing outline gerber') + outline = gerber.loads(outline_gerber) + (minx, maxx), (miny, maxy) = outline.bounds + grbw, grbh = maxx - minx, maxy - miny + status_print(' * outline has offset {}, size {}'.format((minx, miny), (grbw, grbh))) + + # Parse target layer + status_print('Parsing target gerber') + target = gerber.loads(target_gerber) + (tminx, tmaxx), (tminy, tmaxy) = target.bounds + status_print(' * target layer has offset {}, size {}'.format((tminx, tminy), (tmaxx-tminx, tmaxy-tminy))) + + # Read source image + imgh, imgw = source_img.shape + scale = math.ceil(max(imgw/grbw, imgh/grbh)) # scale is in dpmm + status_print(' * source image has size {}, going for scale {}dpmm'.format((imgw, imgh), scale)) + + # Merge layers to target mask + target_img = generate_mask(outline, target, scale, debugimg, status_print, gerber_unit, extend_overlay_r_mil, subtract_gerber) + + # Threshold source image. Ideally, the source image is already binary but in case it's not, or in case it's not + # exactly binary (having a few very dark or very light grays e.g. due to JPEG compression) we're thresholding here. + status_print('Thresholding source image') + qr = 1+2*max(1, int(extend_picture_r_mil/1000 * scale)) + source_img = source_img[::-1] + _, source_img = cv2.threshold(source_img, 127, 255, cv2.THRESH_BINARY) + debugimg(source_img, 'thresh') + + # Pad image to size of target layer images generated above. After this, `scale` applies to the padded image as well + # as the gerber renders. For padding, zoom or shrink the image to completely fit the gerber's rectangular bounding + # box. Center the image vertically or horizontally if it has a different aspect ratio. + status_print('Padding source image') + tgth, tgtw = target_img.shape + padded_img = np.zeros(shape=target_img.shape, dtype=source_img.dtype) + offx = int((minx-tminx if tminx < minx else 0)*scale) + offy = int((miny-tminy if tminy < miny else 0)*scale) + offx += int(grbw*scale - imgw) // 2 + offy += int(grbh*scale - imgh) // 2 + endx, endy = min(offx+imgw, tgtw), min(offy+imgh, tgth) + print('off', (offx, offy), 'end', (endx, endy), 'img', (imgw, imgh), 'tgt', (tgtw, tgth)) + padded_img[offy:endy, offx:endx] = source_img[:endy-offy, :endx-offx] + debugimg(padded_img, 'padded') + debugimg(target_img, 'target') + + # Mask out excluded gerber features (source silk, holes, solder mask etc.) from the target image + status_print('Masking source image') + out_img = (np.multiply((padded_img/255.0), (target_img/255.0) * -1 + 1) * 255).astype(np.uint8) + + debugimg(out_img, 'multiplied') + + # Calculate contours from masked target image and plot them to the target gerber context + status_print('Calculating contour lines') + plot_contours(out_img, + target, + offx=(tminx, tminy), + scale=scale, + status_print=lambda *args: status_print(' ', *args)) + + # Write target gerber context to disk + status_print('Generating output gerber') + from gerber.render import rs274x_backend + ctx = rs274x_backend.Rs274xContext(target.settings) + target.render(ctx) + out = ctx.dump().getvalue() + status_print('Done.') + return out + + +def plot_contours( + img:np.ndarray, + layer:gerber.rs274x.GerberFile, + offx:tuple, + scale:float, + debug=lambda *args:None, + status_print=lambda *args:None): + imgh, imgw = img.shape + + # Extract contour hierarchy using OpenCV + status_print('Extracting contours') + img_cont_out, contours, hierarchy = cv2.findContours(img, cv2.RETR_TREE, cv2.CHAIN_APPROX_TC89_KCOS) + + aperture = list(layer.apertures)[0] + + from gerber.primitives import Line, Region + status_print('offx', offx, 'scale', scale) + + xbias, ybias = offx + def map(coord): + x, y = coord + return (x/scale + xbias, y/scale + ybias) + def contour_lines(c): + return [ Line(map(start), map(end), aperture, level_polarity='dark', units=layer.settings.units) + for start, end in zip(c, np.vstack((c[1:], c[:1]))) ] + + done = [] + process_stack = [-1] + next_process_stack = [] + parents = [ (i, first_child != -1, parent) for i, (_1, _2, first_child, parent) in enumerate(hierarchy[0]) ] + is_dark = True + status_print('Converting contours to gerber primitives') + with tqdm.tqdm(total=len(contours)) as progress: + while len(done) != len(contours): + for i, has_children, parent in parents[:]: + if parent in process_stack: + contour = contours[i] + polarity = 'dark' if is_dark else 'clear' + debug('rendering {} with parent {} as {} with {} vertices'.format(i, parent, polarity, len(contour))) + debug('process_stack is', process_stack) + debug() + layer.primitives.append(Region(contour_lines(contour[:,0]), level_polarity=polarity, units=layer.settings.units)) + if has_children: + next_process_stack.append(i) + done.append(i) + parents.remove((i, has_children, parent)) + progress.update(1) + debug('skipping to next level') + process_stack, next_process_stack = next_process_stack, [] + is_dark = not is_dark + debug('done', done) + +# Utility foo +# =========== + +def find_gerber_in_dir(dir_path, extensions, exclude=''): + contents = os.listdir(dir_path) + exts = extensions.split('|') + excs = exclude.split('|') + for entry in contents: + if any(entry.lower().endswith(ext.lower()) for ext in exts) and not any(entry.lower().endswith(ex) for ex in excs if exclude): + lname = path.join(dir_path, entry) + if not path.isfile(lname): + continue + with open(lname, 'r') as f: + return lname, f.read() + + raise ValueError(f'Cannot find file with suffix {extensions} in dir {dir_path}') + +# Gerber file name extensions for Altium/Protel | KiCAD | Eagle +LAYER_SPEC = { + 'top': { + 'paste': '.gtp|-F.Paste.gbr|.pmc', + 'silk': '.gto|-F.SilkS.gbr|.plc', + 'mask': '.gts|-F.Mask.gbr|.stc', + 'copper': '.gtl|-F.Cu.bgr|.cmp', + 'outline': '.gm1|-Edge.Cuts.gbr|.gmb', + }, + 'bottom': { + 'paste': '.gbp|-B.Paste.gbr|.pms', + 'silk': '.gbo|-B.SilkS.gbr|.pls', + 'mask': '.gbs|-B.Mask.gbr|.sts', + 'copper': '.gbl|-B.Cu.bgr|.sol', + 'outline': '.gm1|-Edge.Cuts.gbr|.gmb' + }, + } + +# Command line interface +# ====================== + +def process_gerbers(source, target, image, side, layer, debugdir): + if not os.path.isdir(source): + raise ValueError(f'Given source "{source}" is not a directory.') + + # Load input files + source_img = cv2.imread(image, cv2.IMREAD_GRAYSCALE) + if source_img is None: + print(f'"{image}" is not a valid image file', file=sys.stderr) + sys.exit(1) + + tlayer, slayer = { + 'silk': ('silk', 'mask'), + 'mask': ('mask', 'silk'), + 'copper': ('copper', None) + }[layer] + + layers = LAYER_SPEC[side] + tname, tgrb = find_gerber_in_dir(source, layers[tlayer]) + print('Target layer file {}'.format(os.path.basename(tname))) + oname, ogrb = find_gerber_in_dir(source, layers['outline']) + print('Outline layer file {}'.format(os.path.basename(oname))) + subtract = find_gerber_in_dir(source, layers[slayer]) if slayer else None + + # Prepare output. Do this now to error out as early as possible if there's a problem. + if os.path.exists(target): + if os.path.isdir(target) and sorted(os.listdir(target)) == sorted(os.listdir(source)): + shutil.rmtree(target) + else: + print('Error: Target already exists and does not look like source. Please manually remove the target dir before proceeding.', file=sys.stderr) + sys.exit(1) + + # Generate output + out = paste_image(tgrb, ogrb, source_img, [subtract], debugdir=debugdir, status_print=lambda *args: print(*args, flush=True)) + + shutil.copytree(source, target) + with open(os.path.join(target, os.path.basename(tname)), 'w') as f: + f.write(out) + +def render_preview(source, image, side, process_resolution, resolution_oversampling): + def load_layer(layer): + name, grb = find_gerber_in_dir(source, LAYER_SPEC[side][layer]) + print(f'{layer} layer file {os.path.basename(name)}') + return grb + + outline = load_layer('outline') + silk = load_layer('silk') + mask = load_layer('mask') + copper = load_layer('copper') + + try: + nm, npth = find_gerber_in_dir(source, '-npth.drl') + print(f'npth drill file {nm}') + except ValueError: + npth = None + nm, drill = find_gerber_in_dir(source, '.drl|.txt', exclude='-npth.drl') + print(f'drill file {nm}') + drill = ([npth] if npth else []) + [drill] + + generate_template( + silk, mask, copper, outline, drill, + image, + gerber_unit=Unit.MM, + process_resolution=process_resolution, + resolution_oversampling=resolution_oversampling, + ) + +if __name__ == '__main__': + # Parse command line arguments + import argparse + parser = argparse.ArgumentParser() + + subcommand = parser.add_subparsers(help='Sub-commands') + subcommand.required, subcommand.dest = True, 'command' + vectorize_parser = subcommand.add_parser('vectorize', help='Vectorize bitmap image onto gerber layer') + render_parser = subcommand.add_parser('render', help='Render bitmap preview of board suitable as a template for positioning and scaling the input image') + + parser.add_argument('-d', '--debugdir', type=str, default=None, help='Directory to place intermediate images into for debuggin') + + vectorize_parser.add_argument('side', choices=['top', 'bottom'], help='Target board side') + vectorize_parser.add_argument('--layer', '-l', choices=['silk', 'mask', 'copper'], default='silk', help='Target layer on given side') + + vectorize_parser.add_argument('source', help='Source gerber directory') + vectorize_parser.add_argument('target', help='Target gerber directory') + vectorize_parser.add_argument('image', help='Image to render') + + render_parser.add_argument('--fab-resolution', '-r', type=float, nargs='?', default=6.0, help='Smallest feature size supported by PCB manufacturer, in mil. On silkscreen layers, this is the minimum font stroke width.') + render_parser.add_argument('--oversampling', '-o', type=float, nargs='?', default=10, help='Oversampling factor for the image. If set to say, 10 pixels, one minimum feature size (see --fab-resolution) will be 10 pixels long. The input image for vectorization should not contain any detail of smaller pixel size than this number in order to be manufacturable.') + render_parser.add_argument('side', choices=['top', 'bottom'], help='Target board side') + render_parser.add_argument('source', help='Source gerber directory') + render_parser.add_argument('image', help='Output image filename') + args = parser.parse_args() + + #try: + if args.command == 'vectorize': + process_gerbers(args.source, args.target, args.image, args.side, args.layer, args.debugdir) + else: # command == render + render_preview(args.source, args.image, args.side, args.fab_resolution, args.oversampling) + #except ValueError as e: + # print(*e.args, file=sys.stderr) + # sys.exit(1) + |