#!/usr/bin/env python3 import tempfile import os.path as path import os import sys import time import shutil import math 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, )