diff --git a/python/commands/routing.py b/python/commands/routing.py
index b84f4c1..563314d 100644
--- a/python/commands/routing.py
+++ b/python/commands/routing.py
@@ -1095,11 +1095,25 @@ class RoutingCommands:
                     y1 = board_box.GetY() / scale
                     x2 = (board_box.GetX() + board_box.GetWidth()) / scale
                     y2 = (board_box.GetY() + board_box.GetHeight()) / scale
+
+                    # Detect corner radius from Edge.Cuts arcs so the zone rectangle
+                    # stays inside the rounded board corners (avoids zone visually
+                    # extending outside Edge.Cuts before refill)
+                    corner_radius = 0.0
+                    edge_layer_id = self.board.GetLayerID("Edge.Cuts")
+                    for item in self.board.GetDrawings():
+                        if item.GetLayer() == edge_layer_id and item.GetClass() == "PCB_ARC":
+                            r = item.GetRadius() / scale
+                            if r > corner_radius:
+                                corner_radius = r
+                    # Inset the zone rectangle by the corner radius so its corners
+                    # lie on the straight portions of the board edge.
+                    inset = corner_radius
                     points = [
-                        {"x": x1, "y": y1},
-                        {"x": x2, "y": y1},
-                        {"x": x2, "y": y2},
-                        {"x": x1, "y": y2},
+                        {"x": x1 + inset, "y": y1 + inset},
+                        {"x": x2 - inset, "y": y1 + inset},
+                        {"x": x2 - inset, "y": y2 - inset},
+                        {"x": x1 + inset, "y": y2 - inset},
                     ]
                 else:
                     return {
diff --git a/src/tools/registry.ts b/src/tools/registry.ts
index 6eec4fb..ddb307e 100644
--- a/src/tools/registry.ts
+++ b/src/tools/registry.ts
@@ -228,16 +228,24 @@ export function searchTools(query: string): SearchResult[] {
   const q = query.toLowerCase();
   const matches: SearchResult[] = [];
 
-  // This is a placeholder - we'll populate descriptions from actual tool definitions
-  // For now, we'll search by name and category
+  // Search direct tools first
+  for (const toolName of directToolNames) {
+    if (toolName.toLowerCase().includes(q)) {
+      matches.push({
+        category: "direct",
+        tool: toolName,
+        description: `${toolName} (direct tool — call directly, no execute_tool needed)`
+      });
+    }
+  }
+
+  // Search routed tools by name and category
   for (const category of toolCategories) {
-    // Check if category name or description matches
     const categoryMatch =
       category.name.toLowerCase().includes(q) ||
       category.description.toLowerCase().includes(q);
 
     for (const toolName of category.tools) {
-      // Check if tool name matches or category matches
       if (toolName.toLowerCase().includes(q) || categoryMatch) {
         matches.push({
           category: category.name,