Gerber export writes drill files in Excellon format, picked by a constant in GerberExporter, through gerber-writer 1.2.0; a Drill Hole no longer adds its outline and crosshair to the drill file

diylc/diylc-core/pom.xml

@@ -97,10 +97,10 @@
         </dependency>
         <dependency>
             <groupId>org.diylc.local</groupId>
-            <artifactId>gerber-writer-api-1.1.0</artifactId>
+            <artifactId>gerber-writer-api-1.2.0</artifactId>
             <version>1.0</version>
             <scope>system</scope>
-            <systemPath>${project.basedir}/../lib/gerber-writer-api-1.1.0.jar</systemPath>
+            <systemPath>${project.basedir}/../lib/gerber-writer-api-1.2.0.jar</systemPath>
         </dependency>
         <dependency>
             <groupId>org.diylc.local</groupId>

diylc/diylc-core/src/main/java/org/diylc/core/gerber/GerberExporter.java

@@ -15,6 +15,7 @@ import java.util.stream.Collectors;
 import org.apache.log4j.Logger;
 
 import com.bancika.gerberwriter.DataLayer;
+import com.bancika.gerberwriter.DrillFormat;
 
 import org.diylc.common.PCBLayer;
 import org.diylc.core.ComponentState;
@@ -32,6 +33,9 @@ public class GerberExporter {
   public static final double OUTLINE_THICKNESS = new Size(0.3d, SizeUnit.mm).convertToPixels();
   private static final Logger LOG = Logger.getLogger(GerberExporter.class);
 
+  // Excellon is the drill format every fab accepts; Gerber drill files are not read by all of them
+  private static final DrillFormat DRILL_FORMAT = DrillFormat.EXCELLON;
+
   public static void exportGerber(String fileNameBase, Project currentProject, IView view,
                                   Graphics2D graphics2d, String diylcVersion) {
 
@@ -137,6 +141,23 @@ public class GerberExporter {
           return;
         }
       });
+
+      g2d.getDrillLayerMap().forEach((layer, drillLayer) -> {
+        try {
+          String fileName = layer.formatFileName(fileNameBase, boardComponent.getName(),
+                  DRILL_FORMAT == DrillFormat.EXCELLON ? "drl" : "gbr");
+          LOG.info("Exporting layer: " + layer + " for board " + boardComponent.getName()
+                  + " to file: " + fileName);
+          drillLayer.dumpToFile(fileName, DRILL_FORMAT);
+          generatedFiles.add(fileName);
+        } catch (IOException e) {
+          LOG.error("Error writing drill file: " + e.getMessage());
+          view.showMessage(
+                  LangUtil.translate(
+                          "Failed to export the project to gerber. Please check the log for details"),
+                  LangUtil.translate("Gerber Export"), IView.ERROR_MESSAGE);
+        }
+      });
     });
     view.showMessage(
             String.format(

diylc/diylc-core/src/main/java/org/diylc/core/gerber/GerberG2DWrapper.java

@@ -21,6 +21,7 @@ import java.awt.font.GlyphVector;
 import java.awt.geom.AffineTransform;
 import java.awt.geom.Ellipse2D;
 import java.awt.geom.Line2D;
+import java.awt.geom.Point2D;
 import java.awt.geom.Rectangle2D;
 import java.awt.image.BufferedImage;
 import java.awt.image.BufferedImageOp;
@@ -32,6 +33,7 @@ import java.util.HashMap;
 import java.util.Map;
 
 import com.bancika.gerberwriter.DataLayer;
+import com.bancika.gerberwriter.DrillLayer;
 import com.bancika.gerberwriter.Point;
 import com.bancika.gerberwriter.padmasters.Circle;
 
@@ -45,6 +47,7 @@ public class GerberG2DWrapper extends Graphics2D
   private static final double CURVE_APPROXIMATION_TOLERANCE = 1d;
 
   private Map<GerberLayer, DataLayer> layerMap;
+  private Map<GerberLayer, DrillLayer> drillLayerMap;
   private boolean trackingGerber = false;
   private Map<GerberLayer, GerberProperties> currentLayers =
       new HashMap<GerberLayer, GerberProperties>();
@@ -65,6 +68,7 @@ public class GerberG2DWrapper extends Graphics2D
     this.graphics2d = graphics2d;
     this.boardRect = boardRect;
     this.layerMap = new HashMap<GerberLayer, DataLayer>();
+    this.drillLayerMap = new HashMap<GerberLayer, DrillLayer>();
     this.diylcVersion = diylcVersion;
   }
 
@@ -115,7 +119,11 @@ public class GerberG2DWrapper extends Graphics2D
 
   @Override
   public void startGerberOutput(GerberLayer layer, String function, boolean negative) {
+    if (layer.isDrill()) {
+      drillLayerMap.computeIfAbsent(layer, k -> layer.buildDrillLayer(diylcVersion));
+    } else {
       layerMap.computeIfAbsent(layer, k -> layer.buildLayer(diylcVersion));
+    }
     currentLayers.put(layer, new GerberProperties(function, negative));
     trackingGerber = true;
   }
@@ -155,6 +163,10 @@ public class GerberG2DWrapper extends Graphics2D
     return layerMap;
   }
 
+  public Map<GerberLayer, DrillLayer> getDrillLayerMap() {
+    return drillLayerMap;
+  }
+
   /**
    * Sets whether text is written mirrored, each string about its own centre. The output is in top
    * view, so text on the bottom side has to be mirrored to read correctly once the board is turned
@@ -168,6 +180,11 @@ public class GerberG2DWrapper extends Graphics2D
   public void draw(Shape s) {
     if (trackingGerber && !getColor().equals(Constants.TRANSPARENT_COLOR)) {
       currentLayers.entrySet().forEach(entry -> {
+        // only round fills are holes; outlines, such as a drill hole marker's border and
+        // crosshair, are not drilled
+        if (entry.getKey().isDrill()) {
+          return;
+        }
         double width = 1;
         if (stroke != null && stroke instanceof BasicStroke) {
           width = ((BasicStroke) stroke).getLineWidth();
@@ -222,6 +239,10 @@ public class GerberG2DWrapper extends Graphics2D
   public void fillShape(Shape s) {
     if (trackingGerber && !getColor().equals(Constants.TRANSPARENT_COLOR)) {
       currentLayers.entrySet().forEach(entry -> {
+        // only round fills are holes
+        if (entry.getKey().isDrill()) {
+          return;
+        }
         DataLayer dataLayer = layerMap.get(entry.getKey());
         AffineTransform finalTx = getFinalTx(entry.getKey().isMirrored());
         GerberPathRenderer.outputPathArea(s.getPathIterator(finalTx), dataLayer,
@@ -234,6 +255,10 @@ public class GerberG2DWrapper extends Graphics2D
   private void fillFlash(Ellipse2D c) {
     if (trackingGerber && !getColor().equals(Constants.TRANSPARENT_COLOR)) {
       currentLayers.entrySet().forEach(entry -> {
+        if (entry.getKey().isDrill()) {
+          addHole(c, entry.getKey(), entry.getValue().function);
+          return;
+        }
         DataLayer dataLayer = layerMap.get(entry.getKey());
         AffineTransform finalTx = getFinalTx(entry.getKey().isMirrored());
         if (Math.abs(c.getWidth() - c.getHeight()) < 0.1 && finalTx.getShearX() == 0
@@ -255,6 +280,17 @@ public class GerberG2DWrapper extends Graphics2D
     }
   }
 
+  private void addHole(Ellipse2D c, GerberLayer layer, String function) {
+    AffineTransform finalTx = getFinalTx(layer.isMirrored());
+    Point2D center = finalTx.transform(new Point2D.Double(c.getCenterX(), c.getCenterY()), null);
+    double factor = SizeUnit.px.getFactor();
+    // the drawing transform scales evenly, so the circle stays a circle, scaled by the square root
+    // of the determinant whether or not it is also rotated
+    double diameter = c.getWidth() * Math.sqrt(Math.abs(finalTx.getDeterminant())) * factor;
+    drillLayerMap.get(layer).addHole(new Point(center.getX() * factor, center.getY() * factor),
+        diameter, function);
+  }
+
   private AffineTransform getFinalTx(boolean isMirrored) {
     AffineTransform finalTx = new AffineTransform();
     if (isMirrored) {

diylc/diylc-core/src/main/java/org/diylc/core/gerber/GerberLayer.java

@@ -1,6 +1,7 @@
 package org.diylc.core.gerber;
 
 import com.bancika.gerberwriter.DataLayer;
+import com.bancika.gerberwriter.DrillLayer;
 import com.bancika.gerberwriter.GenerationSoftware;
 
 public enum GerberLayer {
@@ -30,9 +31,18 @@ public enum GerberLayer {
   }
   
   public DataLayer buildLayer(String diylcVersion) {
-    GenerationSoftware genSoftware =
-        new GenerationSoftware("bancika", "DIY Layout Creator", diylcVersion);
-    return new DataLayer(function, negative, genSoftware);
+    return new DataLayer(function, negative, createGenerationSoftware(diylcVersion));
+  }
+
+  public DrillLayer buildDrillLayer(String diylcVersion) {
+    return new DrillLayer(this == DrillPlated, createGenerationSoftware(diylcVersion));
+  }
+
+  /**
+   * @return true for the drill layers, which hold holes rather than drawn copper or graphics
+   */
+  public boolean isDrill() {
+    return this == DrillPlated || this == DrillNonPlated;
   }
   
   public String getExtension() {
@@ -56,7 +66,15 @@ public enum GerberLayer {
   }
 
   public String formatFileName(String fileNameBase, String boardName) {
+    return formatFileName(fileNameBase, boardName, getExtension());
+  }
+
+  public String formatFileName(String fileNameBase, String boardName, String extension) {
     return fileNameBase + (fileNameBase.endsWith(".") ? "" : ".")
-        + boardName + "-" + getSuffix() + "." + getExtension();
+        + boardName + "-" + getSuffix() + "." + extension;
+  }
+
+  private static GenerationSoftware createGenerationSoftware(String diylcVersion) {
+    return new GenerationSoftware("bancika", "DIY Layout Creator", diylcVersion);
   }
 }

diylc/diylc-core/src/main/resources/update.xml

@@ -673,6 +673,10 @@
 					<changeType>IMPROVEMENT</changeType>
 					<description>Gerber export no longer cuts the holes of solder pads and vias out of the copper layers; the holes are defined by the drill files alone, as the Gerber specification recommends</description>
 				</org.diylc.appframework.update.Change>
+				<org.diylc.appframework.update.Change>
+					<changeType>IMPROVEMENT</changeType>
+					<description>Gerber export writes the drill files in Excellon format, the drill format every PCB fab accepts, instead of Gerber format; a 'Drill Hole' no longer adds its outline and crosshair to the drill file</description>
+				</org.diylc.appframework.update.Change>
 				<org.diylc.appframework.update.Change>
 					<changeType>BUG_FIX</changeType>
 					<description>Rotated labels in pasted components and building blocks were drawn in the wrong place and at the wrong angle while following the mouse, until the components were placed</description>

diylc/diylc-library/pom.xml

@@ -73,10 +73,10 @@
         </dependency>
         <dependency>
             <groupId>org.diylc.local</groupId>
-            <artifactId>gerber-writer-api-1.1.0</artifactId>
+            <artifactId>gerber-writer-api-1.2.0</artifactId>
             <version>1.0</version>
             <scope>system</scope>
-            <systemPath>${project.basedir}/../lib/gerber-writer-api-1.1.0.jar</systemPath>
+            <systemPath>${project.basedir}/../lib/gerber-writer-api-1.2.0.jar</systemPath>
         </dependency>
         <dependency>
             <groupId>org.diylc.local</groupId>

diylc/diylc-library/src/main/java/org/diylc/components/connectivity/Via.java

@@ -71,9 +71,6 @@ public class Via extends AbstractTransparentComponent<Void>
   public static Size HOLE_SIZE = new Size(0.4d, SizeUnit.mm);
   public static Color COLOR = Color.black;
 
-  // gerber-writer has no constant for it
-  private static final String VIA_DRILL = "ViaDrill";
-
   private Size size = SIZE;
   private Size holeSize = HOLE_SIZE;
   private Color color = COLOR;
@@ -112,7 +109,8 @@ public class Via extends AbstractTransparentComponent<Void>
     if (gerberDrawingObserver != null) {
       gerberDrawingObserver.stopGerberOutput(GerberLayer.CopperTop);
       gerberDrawingObserver.stopGerberOutput(GerberLayer.CopperBot);
-      gerberDrawingObserver.startGerberOutput(GerberLayer.DrillPlated, VIA_DRILL, false);
+      gerberDrawingObserver.startGerberOutput(GerberLayer.DrillPlated, GerberFunctions.VIA_DRILL,
+          false);
     }
     g2d.setColor(Constants.CANVAS_COLOR);
     g2d.fill(new Ellipse2D.Double(point.getX() - holeDiameter / 2,

diylc/diylc-library/src/test/java/org/diylc/components/connectivity/SolderPadGerberTest.java

@@ -21,18 +21,20 @@
 */
 package org.diylc.components.connectivity;
 
+import static org.junit.Assert.assertEquals;
 import static org.junit.Assert.assertFalse;
 import static org.junit.Assert.assertTrue;
 
 import java.awt.Graphics2D;
 import java.awt.geom.Rectangle2D;
 import java.awt.image.BufferedImage;
-import java.util.Map;
+import java.util.EnumSet;
 import java.util.Set;
 
-import com.bancika.gerberwriter.DataLayer;
+import com.bancika.gerberwriter.DrillFormat;
 
 import org.diylc.common.PCBLayer;
+import org.diylc.components.electromechanical.DrillHole;
 import org.diylc.core.ComponentState;
 import org.diylc.core.Project;
 import org.diylc.core.gerber.GerberG2DWrapper;
@@ -79,7 +81,7 @@ public class SolderPadGerberTest {
   @Test
   public void testViaIsOnBothLayersAndTented() {
     Via via = new Via();
-    Set<GerberLayer> layers = drawGerber(via).keySet();
+    Set<GerberLayer> layers = layersOf(drawGerber(via));
     assertTrue(layers.contains(GerberLayer.CopperTop));
     assertTrue(layers.contains(GerberLayer.CopperBot));
     assertTrue(layers.contains(GerberLayer.DrillPlated));
@@ -95,11 +97,32 @@ public class SolderPadGerberTest {
     assertNoCutOut(drawGerber(new Via()));
   }
 
+  @Test
+  public void testViaIsDrilledOnceAsViaDrill() {
+    String excellon = drawGerber(new Via()).getDrillLayerMap().get(GerberLayer.DrillPlated)
+        .dumpToString(DrillFormat.EXCELLON);
+    assertTrue(excellon.contains("; #@! TA.AperFunction,Plated,PTH,ViaDrill\nT1C0.4\n"));
+    assertEquals(1, countHoles(excellon));
+  }
+
+  @Test
+  public void testDrillHoleMarkerIsDrilledOnce() {
+    // the marker's border and crosshair are drawn too, but they are not holes
+    String excellon = drawGerber(new DrillHole()).getDrillLayerMap()
+        .get(GerberLayer.DrillNonPlated).dumpToString(DrillFormat.EXCELLON);
+    assertTrue(excellon.contains("T1C3.0\n"));
+    assertEquals(1, countHoles(excellon));
+  }
+
+  private static long countHoles(String excellon) {
+    return excellon.lines().filter(line -> line.startsWith("X")).count();
+  }
+
   // a cut-out is drawn with clear polarity, %LPC*%
-  private static void assertNoCutOut(Map<GerberLayer, DataLayer> layers) {
+  private static void assertNoCutOut(GerberG2DWrapper g2d) {
     for (GerberLayer copperLayer : new GerberLayer[] {GerberLayer.CopperTop,
         GerberLayer.CopperBot}) {
-      String gerber = layers.get(copperLayer).dumpGerberToString();
+      String gerber = g2d.getLayerMap().get(copperLayer).dumpGerberToString();
       assertTrue(gerber.contains("D03*"));
       assertFalse(gerber.contains("%LPC*%"));
     }
@@ -113,10 +136,17 @@ public class SolderPadGerberTest {
     SolderPad pad = new SolderPad();
     pad.setLayer(layer);
     pad.setHoleType(holeType);
-    return drawGerber(pad).keySet();
+    return layersOf(drawGerber(pad));
   }
 
-  private static Map<GerberLayer, DataLayer> drawGerber(IGerberComponentCustom component) {
+  private static Set<GerberLayer> layersOf(GerberG2DWrapper g2d) {
+    Set<GerberLayer> layers = EnumSet.noneOf(GerberLayer.class);
+    layers.addAll(g2d.getLayerMap().keySet());
+    layers.addAll(g2d.getDrillLayerMap().keySet());
+    return layers;
+  }
+
+  private static GerberG2DWrapper drawGerber(IGerberComponentCustom component) {
     BufferedImage img = new BufferedImage(100, 100, BufferedImage.TYPE_INT_ARGB);
     Graphics2D graphics = img.createGraphics();
     GerberG2DWrapper g2d =
@@ -124,6 +154,6 @@ public class SolderPadGerberTest {
     g2d.startedDrawingComponent();
     component.draw(g2d, ComponentState.NORMAL, false, new Project(), g2d, g2d);
     graphics.dispose();
-    return g2d.getLayerMap();
+    return g2d;
   }
 }

diylc/diylc-swing/pom.xml

@@ -140,10 +140,10 @@
         </dependency>
         <dependency>
             <groupId>org.diylc.local</groupId>
-            <artifactId>gerber-writer-api-1.1.0</artifactId>
+            <artifactId>gerber-writer-api-1.2.0</artifactId>
             <version>1.0</version>
             <scope>system</scope>
-            <systemPath>${project.basedir}/../lib/gerber-writer-api-1.1.0.jar</systemPath>
+            <systemPath>${project.basedir}/../lib/gerber-writer-api-1.2.0.jar</systemPath>
         </dependency>
         <dependency>
             <groupId>org.diylc.local</groupId>