fix: size hand-placed vias from the board's via minimums

lib/components/normal-components/Board/Board.ts

@@ -252,6 +252,35 @@ export class Board
     }
   }
 
+  /**
+   * Via hole/pad diameters (mm) required by this board's design rules:
+   * minViaHoleDiameter/minViaPadDiameter, then the board's pcbStyle via size,
+   * then JLCPCB's minimums. These are recorded on pcb_board and are the
+   * default size for vias placed without an explicit or styled size.
+   */
+  _getResolvedMinViaDiameters(): { holeDiameter: number; padDiameter: number } {
+    const subcircuitProps = this.getSubcircuit()._parsedProps
+    const pcbStyle = this.getInheritedMergedProperty("pcbStyle")
+    const styledViaDimensions = getViaDiameterDefaults(pcbStyle)
+    const configuredViaHoleDiameter =
+      subcircuitProps.minViaHoleDiameter ??
+      (pcbStyle?.viaHoleDiameter !== undefined
+        ? styledViaDimensions.holeDiameter
+        : undefined)
+    return {
+      holeDiameter:
+        configuredViaHoleDiameter ?? jlcMinTolerances.min_via_hole_diameter!,
+      padDiameter:
+        subcircuitProps.minViaPadDiameter ??
+        (pcbStyle?.viaPadDiameter !== undefined
+          ? styledViaDimensions.padDiameter
+          : configuredViaHoleDiameter !== undefined
+            ? configuredViaHoleDiameter +
+              DEFAULT_VIA_PAD_DIAMETER_OVER_HOLE_DIAMETER_MM
+            : jlcMinTolerances.min_via_pad_diameter!),
+    }
+  }
+
   doInitialPcbBoardAutoSize(): void {
     if (this.root?.pcbDisabled) return
     if (!this.pcb_board_id) return
@@ -584,23 +613,10 @@ export class Board
       }
     }
     const subcircuitProps = this.getSubcircuit()._parsedProps
-    const pcbStyle = this.getInheritedMergedProperty("pcbStyle")
-    const styledViaDimensions = getViaDiameterDefaults(pcbStyle)
-    const configuredViaHoleDiameter =
-      subcircuitProps.minViaHoleDiameter ??
-      (pcbStyle?.viaHoleDiameter !== undefined
-        ? styledViaDimensions.holeDiameter
-        : undefined)
-    const resolvedMinViaHoleDiameter =
-      configuredViaHoleDiameter ?? jlcMinTolerances.min_via_hole_diameter
-    const resolvedMinViaPadDiameter =
-      subcircuitProps.minViaPadDiameter ??
-      (pcbStyle?.viaPadDiameter !== undefined
-        ? styledViaDimensions.padDiameter
-        : configuredViaHoleDiameter !== undefined
-          ? configuredViaHoleDiameter +
-            DEFAULT_VIA_PAD_DIAMETER_OVER_HOLE_DIAMETER_MM
-          : jlcMinTolerances.min_via_pad_diameter)
+    const {
+      holeDiameter: resolvedMinViaHoleDiameter,
+      padDiameter: resolvedMinViaPadDiameter,
+    } = this._getResolvedMinViaDiameters()
     const pcb_board = db.pcb_board.insert({
       source_board_id: this.source_board_id,
       subcircuit_id: this.subcircuit_id ?? undefined,

lib/components/normal-components/Board/BoardI.ts

@@ -9,5 +9,6 @@ export interface BoardI {
   _generatedStitchingViaIds?: Set<PcbVia["pcb_via_id"]>
   allLayers: ReadonlyArray<LayerRef>
   _getBoardCalcVariables(): Record<string, number>
+  _getResolvedMinViaDiameters?(): { holeDiameter: number; padDiameter: number }
   pcb_board_id?: string | null
 }

lib/components/primitive-components/PcbTrace.ts

@@ -2,7 +2,7 @@ import { type PcbTraceRoutePoint, pcb_trace_route_point } from "circuit-json"
 import { applyToPoint } from "transformation-matrix"
 import { z } from "zod"
 import { getViaSpanLayers } from "lib/utils/getViaSpanLayers"
-import { getViaDiameterDefaults } from "lib/utils/pcbStyle/getViaDiameterDefaults"
+import { getViaDiameterDefaultsForComponent } from "lib/utils/pcbStyle/getViaDiameterDefaults"
 import { PrimitiveComponent } from "../base-components/PrimitiveComponent"
 
 export const pcbTraceProps = z.object({
@@ -87,9 +87,8 @@ export class PcbTrace extends PrimitiveComponent<typeof pcbTraceProps> {
     })
     this.pcb_trace_id = pcb_trace.pcb_trace_id
 
-    const { holeDiameter, padDiameter } = getViaDiameterDefaults(
-      this.getInheritedMergedProperty("pcbStyle"),
-    )
+    const { holeDiameter, padDiameter } =
+      getViaDiameterDefaultsForComponent(this)
     for (const [routeIndex, point] of transformedRoute.entries()) {
       if (point.route_type !== "via") continue
       if (this._materializedRouteViaIndices.has(routeIndex)) continue

lib/components/primitive-components/Trace/Trace_doInitialPcbManualTraceRender.ts

@@ -10,7 +10,7 @@ import type { Port } from "../Port"
 import type { Trace } from "./Trace"
 import { applyToPoint, identity } from "transformation-matrix"
 import { clipTraceEndAtPad } from "../../../utils/trace-clipping/clipTraceEndAtPad"
-import { getViaDiameterDefaults } from "../../../utils/pcbStyle/getViaDiameterDefaults"
+import { getViaDiameterDefaultsForComponent } from "../../../utils/pcbStyle/getViaDiameterDefaults"
 import type { ManualPcbPathPoint } from "lib/utils/pcbTraceRouteToPcbPath"
 import { TraceConnectionError } from "lib/errors"
 import { getPcbSelectorErrorForTracePort } from "./getPcbSelectorErrorForTracePort"
@@ -188,8 +188,8 @@ export function Trace_doInitialPcbManualTraceRender(trace: Trace) {
         subcircuit_id: subcircuit?.subcircuit_id ?? undefined,
         pcb_group_id: trace.getGroup()?.pcb_group_id ?? undefined,
       })
-      const pcbStyle = trace.getInheritedMergedProperty("pcbStyle")
-      const { holeDiameter, padDiameter } = getViaDiameterDefaults(pcbStyle)
+      const { holeDiameter, padDiameter } =
+        getViaDiameterDefaultsForComponent(trace)
       for (let index = 0; index < transformedRoute.length; index++) {
         const point = transformedRoute[index]
         if (point.route_type === "via") {
@@ -485,8 +485,8 @@ export function Trace_doInitialPcbManualTraceRender(trace: Trace) {
   const subcircuitConnectivityMapKey =
     trace.subcircuit_connectivity_map_key ??
     db.source_trace.get(trace.source_trace_id!)?.subcircuit_connectivity_map_key
-  const pcbStyle = trace.getInheritedMergedProperty("pcbStyle")
-  const { holeDiameter, padDiameter } = getViaDiameterDefaults(pcbStyle)
+  const { holeDiameter, padDiameter } =
+    getViaDiameterDefaultsForComponent(trace)
   for (const point of route) {
     if (point.route_type === "via") {
       const fromLayer = point.from_layer as LayerRef

lib/components/primitive-components/Trace/Trace_doInitialPcbTraceRender.ts

@@ -20,7 +20,7 @@ import {
 import { getObstaclesFromCircuitJson } from "lib/utils/obstacles/getObstaclesFromCircuitJson"
 import { pairs } from "lib/utils/pairs"
 import { getRoutePointPosition } from "lib/utils/pcb-trace-route-point-utils"
-import { getViaDiameterDefaults } from "lib/utils/pcbStyle/getViaDiameterDefaults"
+import { getViaDiameterDefaultsForComponent } from "lib/utils/pcbStyle/getViaDiameterDefaults"
 import { reversePcbTraceRoute } from "lib/utils/reverse-pcb-trace-route"
 import { tryNow } from "lib/utils/try-now"
 import type { Port } from "../Port"
@@ -510,8 +510,8 @@ export function Trace_doInitialPcbTraceRender(trace: Trace) {
   const mergedRoute = mergeRoutes(routes)
 
   const traceLength = getTraceLength(mergedRoute)
-  const pcbStyle = trace.getInheritedMergedProperty("pcbStyle")
-  const { holeDiameter, padDiameter } = getViaDiameterDefaults(pcbStyle)
+  const { holeDiameter, padDiameter } =
+    getViaDiameterDefaultsForComponent(trace)
   const pcb_trace = db.pcb_trace.insert({
     route: getCircuitJsonPcbTraceRoute(
       mergedRoute as PcbTraceRoutePointWithSrjMetadata[],

lib/components/primitive-components/Trace/render-pcb-paths.ts

@@ -1,7 +1,7 @@
 import type { PcbPath } from "@tscircuit/props"
 import type { LayerRef } from "circuit-json"
 import { getViaSpanLayers } from "lib/utils/getViaSpanLayers"
-import { getViaDiameterDefaults } from "../../../utils/pcbStyle/getViaDiameterDefaults"
+import { getViaDiameterDefaultsForComponent } from "../../../utils/pcbStyle/getViaDiameterDefaults"
 import type { Port } from "../Port"
 import { getRouteForPcbPath } from "./get-route-for-pcb-path"
 import { insertPcbPathViaContactErrors } from "./insert-pcb-path-via-contact-errors"
@@ -47,8 +47,8 @@ export const renderPcbPaths = ({
     return
   }
 
-  const pcbStyle = trace.getInheritedMergedProperty("pcbStyle")
-  const { holeDiameter, padDiameter } = getViaDiameterDefaults(pcbStyle)
+  const { holeDiameter, padDiameter } =
+    getViaDiameterDefaultsForComponent(trace)
   const connectivityMapKey =
     trace.subcircuit_connectivity_map_key ??
     db.source_trace.get(trace.source_trace_id!)?.subcircuit_connectivity_map_key

lib/components/primitive-components/Via.ts

@@ -1,8 +1,8 @@
-import { type PcbStyle, viaProps } from "@tscircuit/props"
+import { viaProps } from "@tscircuit/props"
 import type { LayerRef, PcbVia } from "circuit-json"
 import { createNetsFromProps } from "lib/utils/components/createNetsFromProps"
 import { getViaSpanLayers } from "lib/utils/getViaSpanLayers"
-import { getViaDiameterDefaultsWithOverrides } from "lib/utils/pcbStyle/getViaDiameterDefaults"
+import { getViaDiameterDefaultsForComponent } from "lib/utils/pcbStyle/getViaDiameterDefaults"
 import { getViaTenting } from "lib/utils/getViaTenting"
 import { z } from "zod"
 import { PrimitiveComponent } from "../base-components/PrimitiveComponent"
@@ -36,21 +36,15 @@ export class Via extends PrimitiveComponent<typeof viaProps> {
     return this._getLayers()
   }
 
-  private _getResolvedViaDiameters(pcbStyle?: PcbStyle) {
-    return getViaDiameterDefaultsWithOverrides(
-      {
-        holeDiameter: this._parsedProps.holeDiameter,
-        padDiameter: this._parsedProps.outerDiameter,
-      },
-      pcbStyle,
-    )
+  private _getResolvedViaDiameters() {
+    return getViaDiameterDefaultsForComponent(this, {
+      holeDiameter: this._parsedProps.holeDiameter,
+      padDiameter: this._parsedProps.outerDiameter,
+    })
   }
 
   getPcbSize(): { width: number; height: number } {
-    const pcbStyle = this.getInheritedMergedProperty("pcbStyle") as
-      | PcbStyle
-      | undefined
-    const { padDiameter } = this._getResolvedViaDiameters(pcbStyle)
+    const { padDiameter } = this._getResolvedViaDiameters()
     return { width: padDiameter, height: padDiameter }
   }
 
@@ -158,10 +152,7 @@ export class Via extends PrimitiveComponent<typeof viaProps> {
   doInitialPcbComponentRender(): void {
     if (this.root?.pcbDisabled) return
     const { db } = this.root!
-    const pcbStyle = this.getInheritedMergedProperty("pcbStyle") as
-      | PcbStyle
-      | undefined
-    const { padDiameter } = this._getResolvedViaDiameters(pcbStyle)
+    const { padDiameter } = this._getResolvedViaDiameters()
     const position = this._getGlobalPcbPositionBeforeLayout()
     const subcircuit = this.getSubcircuit()
     const pcb_component = db.pcb_component.insert({
@@ -264,11 +255,7 @@ export class Via extends PrimitiveComponent<typeof viaProps> {
   doInitialPcbPrimitiveRender(): void {
     if (this.root?.pcbDisabled) return
     const { db } = this.root!
-    const pcbStyle = this.getInheritedMergedProperty("pcbStyle") as
-      | PcbStyle
-      | undefined
-    const { holeDiameter, padDiameter } =
-      this._getResolvedViaDiameters(pcbStyle)
+    const { holeDiameter, padDiameter } = this._getResolvedViaDiameters()
     const position = this._getGlobalPcbPositionBeforeLayout()
     const subcircuit = this.getSubcircuit()
     const connectedNetOrTrace = this._getConnectedNetOrTrace()

lib/utils/pcbStyle/getViaDiameterDefaults.ts

@@ -1,4 +1,5 @@
 import type { PcbStyle } from "@tscircuit/props"
+import type { PrimitiveComponent } from "lib/components/base-components/PrimitiveComponent/PrimitiveComponent"
 
 const DEFAULT_VIA_HOLE_DIAMETER = 0.2
 const DEFAULT_VIA_PAD_DIAMETER = 0.3
@@ -13,26 +14,56 @@ const parseDistance = (
   return Number.isFinite(parsed) ? parsed : fallback
 }
 
-export const getViaDiameterDefaults = (pcbStyle?: PcbStyle) => {
+/** Via drill (hole) and copper pad diameters, in mm */
+type ViaDiameters = { holeDiameter: number; padDiameter: number }
+
+/**
+ * Default via size when a via doesn't specify one. A pcbStyle via size wins,
+ * then the board's resolved via minimums (so hand-placed vias match the vias
+ * the autorouter creates), then the global defaults.
+ */
+export const getViaDiameterDefaults = (
+  pcbStyle?: PcbStyle,
+  boardMinViaDiameters?: ViaDiameters,
+): ViaDiameters => {
   return {
     holeDiameter: parseDistance(
       pcbStyle?.viaHoleDiameter,
-      DEFAULT_VIA_HOLE_DIAMETER,
+      boardMinViaDiameters?.holeDiameter ?? DEFAULT_VIA_HOLE_DIAMETER,
     ),
     padDiameter: parseDistance(
       pcbStyle?.viaPadDiameter,
-      DEFAULT_VIA_PAD_DIAMETER,
+      boardMinViaDiameters?.padDiameter ?? DEFAULT_VIA_PAD_DIAMETER,
     ),
   }
 }
 
 export const getViaDiameterDefaultsWithOverrides = (
   overrides: { holeDiameter?: number; padDiameter?: number },
   pcbStyle?: PcbStyle,
+  boardMinViaDiameters?: ViaDiameters,
 ) => {
-  const defaults = getViaDiameterDefaults(pcbStyle)
+  const defaults = getViaDiameterDefaults(pcbStyle, boardMinViaDiameters)
   return {
     holeDiameter: overrides.holeDiameter ?? defaults.holeDiameter,
     padDiameter: overrides.padDiameter ?? defaults.padDiameter,
   }
 }
+
+/**
+ * Default via size for a via created by `component` (a <via>, a trace's
+ * pcbPath, a <pcbtrace> route...), using its inherited pcbStyle and the
+ * minimums of the board it is on.
+ */
+export const getViaDiameterDefaultsForComponent = (
+  component: Pick<
+    PrimitiveComponent,
+    "getInheritedMergedProperty" | "_getBoard"
+  >,
+  overrides: { holeDiameter?: number; padDiameter?: number } = {},
+) =>
+  getViaDiameterDefaultsWithOverrides(
+    overrides,
+    component.getInheritedMergedProperty("pcbStyle"),
+    component._getBoard()?._getResolvedMinViaDiameters?.(),
+  )

tests/components/primitive-components/via-board-minimum-diameters1.test.tsx

@@ -0,0 +1,76 @@
+import { expect, test } from "bun:test"
+import type { PcbTraceRoutePoint } from "circuit-json"
+import { getTestFixture } from "tests/fixtures/get-test-fixture"
+
+const explicitlySizedRoute = [
+  { route_type: "wire", x: 4, y: 0, width: 0.15, layer: "top" },
+  {
+    route_type: "via",
+    x: 6,
+    y: 0,
+    from_layer: "top",
+    to_layer: "bottom",
+    hole_diameter: 0.45,
+    outer_diameter: 0.9,
+  },
+  { route_type: "wire", x: 8, y: 0, width: 0.15, layer: "bottom" },
+] satisfies PcbTraceRoutePoint[]
+
+test("explicit and pcbStyle via sizes still win over the board's via minimums", async () => {
+  const { circuit } = getTestFixture()
+
+  circuit.add(
+    <board
+      width="20mm"
+      height="10mm"
+      minViaHoleDiameter={0.3}
+      minViaPadDiameter={0.6}
+      routingDisabled
+    >
+      <via
+        pcbX={-6}
+        pcbY={0}
+        fromLayer="top"
+        toLayer="bottom"
+        holeDiameter="0.4mm"
+        outerDiameter="0.8mm"
+      />
+      <group pcbStyle={{ viaHoleDiameter: 0.35, viaPadDiameter: 0.7 }}>
+        <via pcbX={0} pcbY={0} fromLayer="top" toLayer="bottom" />
+      </group>
+      <pcbtrace route={explicitlySizedRoute} />
+      <pcbnotetext
+        pcbX={0}
+        pcbY={4}
+        fontSize={0.4}
+        text="board minVia 0.3/0.6mm keeps explicit and styled sizes"
+      />
+      <pcbnotetext
+        pcbX={-6}
+        pcbY={-1.5}
+        fontSize={0.4}
+        text="explicit 0.4/0.8"
+      />
+      <pcbnotetext
+        pcbX={0}
+        pcbY={-1.5}
+        fontSize={0.4}
+        text="pcbStyle 0.35/0.7"
+      />
+      <pcbnotetext pcbX={6} pcbY={-1.5} fontSize={0.4} text="route 0.45/0.9" />
+    </board>,
+  )
+
+  await circuit.renderUntilSettled()
+
+  expect(
+    circuit.db.pcb_via
+      .list()
+      .map((via) => [via.hole_diameter, via.outer_diameter]),
+  ).toEqual([
+    [0.4, 0.8],
+    [0.35, 0.7],
+    [0.45, 0.9],
+  ])
+  expect(circuit).toMatchPcbSnapshot(import.meta.path)
+})

tests/components/primitive-components/via-board-minimum-diameters2.test.tsx

@@ -0,0 +1,28 @@
+import { expect, test } from "bun:test"
+import { getTestFixture } from "tests/fixtures/get-test-fixture"
+
+test("a board with only minViaHoleDiameter sizes vias like its pcb_board minimums", async () => {
+  const { circuit } = getTestFixture()
+
+  circuit.add(
+    <board width="12mm" height="8mm" minViaHoleDiameter={0.3} routingDisabled>
+      <via pcbX={0} pcbY={0} fromLayer="top" toLayer="bottom" />
+      <pcbnotetext
+        pcbX={0}
+        pcbY={2.5}
+        fontSize={0.45}
+        text="minViaHoleDiameter 0.3mm: via 0.3mm drill / 0.45mm pad"
+      />
+    </board>,
+  )
+
+  await circuit.renderUntilSettled()
+
+  const board = circuit.db.pcb_board.list()[0]
+  const [via] = circuit.db.pcb_via.list()
+  expect([via.hole_diameter, via.outer_diameter]).toEqual([
+    board.min_via_hole_diameter!,
+    board.min_via_pad_diameter!,
+  ])
+  expect(circuit).toMatchPcbSnapshot(import.meta.path)
+})