KiCAD Design Review & Validation Workflow

This skill guides Claude through systematic design review of a KiCAD project using MCP tools. ALL checks are performed through MCP tools — never parse .kicad_sch or .kicad_pcb files directly.

Toolset Loading

Load the required toolsets for design review:

load_toolset('sch_analysis')     # find_orphan_items, find_shorted_nets, find_single_pin_nets
load_toolset('verification')     # run_drc, check_clearance, get_design_rules
load_toolset('sch_export')       # run_erc
load_toolset('pcb_export')       # get_drc_violations
load_toolset('manufacturing')    # validate_for_manufacturing
load_toolset('design_review')    # audit_decoupling, audit_connections, audit_power_rails, etc.

Optional (for deeper analysis):

load_toolset('sch_analysis')     # get net info, trace connections, inspect components
load_toolset('pcb_routing')      # query_traces, get_nets_list

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

Quick Checks (Escalating Severity)

Run these first — they are fast and catch the most critical issues.

Level 1: Structural Integrity

find_orphan_items()

Finds floating wires, labels, and symbols not connected to anything. These are almost always bugs (leftover from edits or incomplete wiring).

Level 2: Critical Net Issues

find_shorted_nets()

Detects nets that are connected together but should not be. A shorted net means:

• Two different net labels on the same wire
• Power rails bridged unintentionally
• Signal nets merged by accident

This is always a critical error. Fix before proceeding.

Level 3: Suspicious Connections

find_single_pin_nets()

A net with only one pin connected is almost always a mistake:

• Incomplete wiring (forgot to connect the other end)
• Orphan net labels (typo in name, so it does not match)
• Leftover stubs from deleted components

Formal Checks

ERC — Electrical Rules Check

run_erc()

Checks schematic-level rules:

• Pin type conflicts (output driving output, unconnected inputs)
• Power pin connections
• Missing no-connect flags
• Duplicate reference designators
• Missing net connections

Review each violation. Some can be waived (e.g., intentional unconnected pins marked with no-connect flag).

DRC — Design Rules Check

get_drc_violations()

Checks PCB-level rules:

• Clearance violations (copper-to-copper, copper-to-edge)
• Minimum trace width violations
• Minimum drill size violations
• Unrouted connections (incomplete routing)
• Zone fill issues
• Courtyard overlaps

Every DRC error must be resolved or explicitly justified before manufacturing.

Design Audits

These go beyond rule checking — they evaluate design quality and best practices.

Decoupling Audit

audit_decoupling()

Checks:

• Every IC power pin has a bypass capacitor
• Capacitor is placed close to the pin (PCB proximity)
• Appropriate capacitor values (100nF ceramic minimum)
• Bulk capacitance present for high-current ICs

Connection Audit

audit_connections()

Checks:

• All expected connections are made
• No nets with unexpected fan-out
• Signal integrity basics (termination on long traces)
• Pull-up/pull-down resistors where required (I2C, reset pins, enable pins)

Power Rail Audit

audit_power_rails()

Checks:

• All power rails have proper source (regulator, connector, etc.)
• Current capacity matches expected load
• Voltage levels are consistent (no 3.3V device on 5V rail)
• Power sequencing considered for multi-rail designs
• Power flags present (avoids ERC false positives)

Manufacturing Audit

audit_manufacturing()

Checks:

• All footprints are fab-house compatible
• Pad sizes meet minimum requirements
• Silkscreen readability
• Test point accessibility
• Fiducial marks present (for SMT assembly)
• Mechanical clearances around mounting holes

Full Review Shortcut

run_design_review()

Runs ALL audits and checks in sequence, producing a consolidated report. Use this for a comprehensive pre-manufacturing review.

Equivalent to running:

1. find_orphan_items
2. find_shorted_nets
3. find_single_pin_nets
4. run_erc
5. get_drc_violations
6. audit_decoupling
7. audit_connections
8. audit_power_rails
9. audit_manufacturing

Severity Classification

CRITICAL — Must fix before manufacturing

WARNING — Should fix, design risk

SUGGESTION — Improvement opportunities

Reporting Format

Present findings grouped by severity with actionable fix suggestions:

## Design Review Results

### CRITICAL (X issues) — Must fix

1. **[Finding title]**
   - Location: [component reference or net name]
   - Issue: [what is wrong]
   - Fix: [specific action to take using MCP tools]

### WARNING (X issues) — Should fix

1. **[Finding title]**
   - Location: [component reference or net name]
   - Issue: [what is wrong]
   - Fix: [specific action to take]

### SUGGESTION (X items) — Optional improvements

1. **[Finding title]**
   - Detail: [what could be better]
   - Action: [suggested improvement]

### Summary
- Critical: X (must resolve)
- Warnings: X (recommended)
- Suggestions: X (optional)
- Verdict: [PASS / FAIL / PASS WITH WARNINGS]

Review Workflow

Quick Review (5-minute check)

1. find_shorted_nets() — catch fatal issues
2. run_erc() — schematic rule check
3. get_drc_violations() — PCB rule check
4. Report findings

Full Review (comprehensive)

1. Load all review toolsets
2. run_design_review() — full audit suite
3. Classify all findings by severity
4. Present report with fix suggestions
5. Offer to fix CRITICAL issues immediately

Pre-Manufacturing Review

1. Full review (above)
2. validate_for_manufacturing() — fab-specific checks
3. Verify BOM completeness
4. Check part availability (if targeting specific fab house)
5. Final verdict: ready to manufacture or not

Rules

1. Never skip quick checks — find_shorted_nets catches the worst bugs fast
2. Classify every finding — severity helps the user prioritize
3. Provide specific fixes — name the MCP tool and parameters to resolve each issue
4. Run DRC after fixes — verify that corrections did not introduce new violations
5. Do not approve a design with CRITICAL issues — even if the user says "it's fine"
6. Load toolsets first — check get_active_toolsets() and load what you need
7. Save before reviewing — ensures checks run against current state
8. Offer to fix — after reporting, offer to use MCP tools to resolve issues
9. Re-run after fixes — always verify fixes resolved the issue and created no new ones
10. Document waivers — if user explicitly waives a warning, note it in the report