KiCAD Manufacturing & Fabrication Workflow

This skill guides Claude through preparing a KiCAD design for manufacturing using Konnect MCP tools. ALL modifications go through MCP tools — never edit project files directly.

Toolset Loading

Before any manufacturing work, load the required toolsets:

load_toolset('pcb_export')       # export_gerber, export_bom, export_position_file, get_drc_violations
load_toolset('manufacturing')    # export_manufacturing_package, validate_for_manufacturing, estimate_cost

Load additional toolsets as needed:

load_toolset('sch_analysis')     # inspect nets, verify footprints assigned
load_toolset('integration')      # search_jlcpcb_parts, suggest_jlcpcb_alternatives
load_toolset('pcb_export')       # export_3d for visual verification

Always call get_active_toolsets() first to see what is already loaded.

Pre-Flight Checklist

Run these checks BEFORE generating any manufacturing outputs. Stop and fix issues at each stage.

1. DRC — Zero Errors Required

get_drc_violations()

• All errors must be resolved. Warnings should be reviewed but may be waived.
• Common blockers: unrouted nets, clearance violations, minimum width violations.
• Do NOT proceed to export if any DRC errors remain.

2. Manufacturing Validation

validate_for_manufacturing()

• Checks board outline is closed
• Checks all pads have copper
• Checks drill sizes are within fabrication limits
• Checks silkscreen does not overlap pads

3. Verify Footprints Assigned

Every schematic symbol must have a footprint assigned. Check for:

• Missing footprint assignments (shows as empty Footprint field)
• Mismatched footprints (wrong pad count for the symbol)
• Non-existent footprint references (library not found)

Export Workflow

One-Shot Export (Recommended)

export_manufacturing_package(output_dir, format)

Generates all manufacturing files in one call:

• Gerbers (all copper layers + mask + silkscreen + edge cuts)
• Drill files (Excellon format)
• BOM (CSV)
• Pick-and-place / component position file (CPL)
• Job file (optional, fab-house specific)

Manual Export (When You Need Control)

Use individual tools when you need specific settings per file:

Step 1: Gerbers

export_gerber(output_dir, layers, options)

Standard layers to export:

• F.Cu, B.Cu (and inner layers if present)
• F.Mask, B.Mask
• F.SilkS, B.SilkS
• F.Paste, B.Paste (for stencils)
• Edge.Cuts (board outline)

Step 2: Bill of Materials

export_bom(output_path, format, fields)

Include fields: Reference, Value, Footprint, LCSC (if targeting JLCPCB).

Step 3: Component Position File

export_position_file(output_path, format, side)

Required for SMT assembly. Contains X/Y/Rotation for each component. Export separately for top and bottom if double-sided assembly.

JLCPCB-Specific Guidance

Part Sourcing

search_jlcpcb_parts(query)           # Find LCSC part numbers
suggest_jlcpcb_alternatives(lcsc_no) # Find alternatives for OOS parts

Part Categories

Strategy: Use basic parts wherever possible. Every extended part adds $3 to assembly cost. Search with search_jlcpcb_parts and filter by basic: true when looking for alternatives.

Minimum Design Rules (JLCPCB Standard Process)

Use add_design_rule or list_design_rules to configure project rules to match.

JLCPCB BOM Requirements

• Column headers must be exactly: Designator, Comment, Footprint, LCSC Part #
• LCSC Part # format: Cxxxxxx (e.g., C14663)
• Group identical parts on one row with comma-separated designators

JLCPCB CPL (Position File) Requirements

• Columns: Designator, Mid X, Mid Y, Layer, Rotation
• Coordinates in millimeters
• Rotation in degrees (0-360)
• Layer values: Top or Bottom

Cost Estimation

estimate_cost(quantity, fab_options)

Factors that increase cost:

• Layer count (2 vs 4 vs 6+)
• Board size
• Number of unique extended parts
• Double-sided assembly
• Special finishes (ENIG vs HASL)
• Tight tolerances below standard minimums
• Expedited turnaround

3D Verification

Before submitting to fab, always generate a 3D view:

export_3d(output_path, format)

Visual checks:

• Component clearance (tall parts near board edges)
• Connector accessibility and orientation
• Mounting hole alignment
• Heatsink/thermal pad clearance
• Enclosure fit (if applicable)

Common Mistakes

1. Exporting with DRC errors — Always run DRC first. A clearance violation can short traces on the fab board.
2. Wrong drill file format — JLCPCB expects Excellon format. PTH and NPTH in separate files.
3. Missing board outline — Edge.Cuts layer must be a closed polygon. Open outlines cause fab rejection.
4. Silkscreen on pads — Silkscreen ink on exposed copper pads prevents soldering. Remove overlaps.
5. Wrong position file origin — CPL origin must match board origin. Use board center or bottom-left corner consistently.
6. Forgetting paste layer — If ordering stencils, F.Paste/B.Paste must be exported.
7. Out-of-stock parts in BOM — Always verify availability with search_jlcpcb_parts before ordering.
8. Rotation offsets — JLCPCB may apply rotation corrections. Review their orientation guide for ICs and polarized components.
9. Panelization not accounted for — If panelizing, export from the panel file, not the individual board.
10. Missing fiducials — SMT assembly with fine-pitch parts requires at least 2 fiducial marks on each assembly side.

Rules

1. Never export without passing DRC — zero errors required
2. Never skip validate_for_manufacturing — catches issues DRC misses
3. Always verify part availability before finalizing BOM for assembly
4. Export 3D model before submitting order — visual sanity check
5. Save project before export — ensures exported files match current state
6. Load toolsets first — check get_active_toolsets() and load what you need
7. Use one-shot export when possible — export_manufacturing_package ensures consistency
8. Double-check fab house requirements — each house has slightly different file format expectations