From 3e329cbf6b4bb2b7a26879cb912b56e4e2bc0308 Mon Sep 17 00:00:00 2001
From: Tom <tomge68@gmail.com>
Date: Sat, 7 Mar 2026 15:46:54 +0100
Subject: [PATCH] fix: route_pad_to_pad auto-inserts via when pads are on
 different copper layers

- Detects F.Cu<->B.Cu layer mismatch in route_pad_to_pad
- Splits route into: trace on start layer + via at midpoint + trace on end layer
- route_trace description warns: use route_pad_to_pad for cross-layer routing
- route_pad_to_pad description highlights automatic via insertion
---
 python/commands/routing.py | 80 +++++++++++++++++++++++++-------------
 src/tools/routing.ts       |  4 +-
 2 files changed, 54 insertions(+), 30 deletions(-)

diff --git a/python/commands/routing.py b/python/commands/routing.py
index befe72f..d630943 100644
--- a/python/commands/routing.py
+++ b/python/commands/routing.py
@@ -144,40 +144,64 @@ class RoutingCommands:
             if not net:
                 net = start_pad.GetNetname() or end_pad.GetNetname() or ""
 
-            # Delegate to route_trace
-            result = self.route_trace(
-                {
-                    "start": {
-                        "x": start_pos.x / scale,
-                        "y": start_pos.y / scale,
-                        "unit": "mm",
-                    },
-                    "end": {
-                        "x": end_pos.x / scale,
-                        "y": end_pos.y / scale,
-                        "unit": "mm",
-                    },
-                    "layer": layer,
-                    "width": width,
-                    "net": net,
-                }
+            # Detect if pads are on different copper layers → need via
+            start_layer = start_pad.GetLayerName()
+            end_layer = end_pad.GetLayerName()
+            copper_layers = {"F.Cu", "B.Cu"}
+            needs_via = (
+                start_layer in copper_layers
+                and end_layer in copper_layers
+                and start_layer != end_layer
             )
 
+            if needs_via:
+                # Place via at midpoint between the two pads
+                via_x = (start_pos.x + end_pos.x) / 2 / scale
+                via_y = (start_pos.y + end_pos.y) / 2 / scale
+
+                # Trace on start layer: start_pad → via
+                r1 = self.route_trace({
+                    "start": {"x": start_pos.x / scale, "y": start_pos.y / scale, "unit": "mm"},
+                    "end":   {"x": via_x, "y": via_y, "unit": "mm"},
+                    "layer": start_layer, "width": width, "net": net,
+                })
+                # Via connecting both layers
+                self.add_via({
+                    "position": {"x": via_x, "y": via_y, "unit": "mm"},
+                    "net": net,
+                    "from_layer": start_layer,
+                    "to_layer": end_layer,
+                })
+                # Trace on end layer: via → end_pad
+                r2 = self.route_trace({
+                    "start": {"x": via_x, "y": via_y, "unit": "mm"},
+                    "end":   {"x": end_pos.x / scale, "y": end_pos.y / scale, "unit": "mm"},
+                    "layer": end_layer, "width": width, "net": net,
+                })
+                success = r1.get("success") and r2.get("success")
+                result = {
+                    "success": success,
+                    "message": f"Routed {from_ref}.{from_pad} → via → {to_ref}.{to_pad} (net: {net}, via at {via_x:.2f},{via_y:.2f})",
+                    "via_added": True,
+                    "via_position": {"x": via_x, "y": via_y},
+                }
+            else:
+                # Same layer — direct trace
+                result = self.route_trace({
+                    "start": {"x": start_pos.x / scale, "y": start_pos.y / scale, "unit": "mm"},
+                    "end":   {"x": end_pos.x / scale, "y": end_pos.y / scale, "unit": "mm"},
+                    "layer": layer if layer else start_layer,
+                    "width": width, "net": net,
+                })
+
             if result.get("success"):
-                result["message"] = (
-                    f"Routed {from_ref}.{from_pad} → {to_ref}.{to_pad} (net: {net or 'none'})"
-                )
                 result["fromPad"] = {
-                    "ref": from_ref,
-                    "pad": from_pad,
-                    "x": start_pos.x / scale,
-                    "y": start_pos.y / scale,
+                    "ref": from_ref, "pad": from_pad,
+                    "x": start_pos.x / scale, "y": start_pos.y / scale,
                 }
                 result["toPad"] = {
-                    "ref": to_ref,
-                    "pad": to_pad,
-                    "x": end_pos.x / scale,
-                    "y": end_pos.y / scale,
+                    "ref": to_ref, "pad": to_pad,
+                    "x": end_pos.x / scale, "y": end_pos.y / scale,
                 }
 
             return result
diff --git a/src/tools/routing.ts b/src/tools/routing.ts
index f086608..309bd2d 100644
--- a/src/tools/routing.ts
+++ b/src/tools/routing.ts
@@ -33,7 +33,7 @@ export function registerRoutingTools(
   // Route trace tool
   server.tool(
     "route_trace",
-    "Route a trace between two points",
+    "Route a trace segment between two XY points on a fixed layer. WARNING: Does NOT handle layer changes — if start and end are on different copper layers, use route_pad_to_pad instead, which automatically inserts a via.",
     {
       start: z
         .object({
@@ -331,7 +331,7 @@ export function registerRoutingTools(
   // Route pad to pad tool
   server.tool(
     "route_pad_to_pad",
-    "Route a trace directly from one component pad to another without needing separate get_pad_position calls. Automatically looks up pad coordinates and uses the pad's net. Saves token usage compared to the 3-step get_pad_position + get_pad_position + route_trace sequence.",
+    "PREFERRED tool for pad-to-pad routing. Looks up pad positions automatically, detects the net from the pad, and — critically — if the two pads are on different copper layers (e.g. J1 on F.Cu and J2 on B.Cu) automatically inserts a via at the midpoint so the connection is complete. Always use this instead of route_trace when routing between named component pads.",
     {
       fromRef: z.string().describe("Reference of the source component (e.g. 'U2')"),
       fromPad: z.union([z.string(), z.number()]).describe("Pad number on the source component (e.g. '6' or 6)"),