Phase-1 board: shrink to 100 × 80 mm, with the BOM's L1 and U7 lands

[udaravima]

Requested by Udara Vimarsha · project thread

Before: the Phase-1 module was 120 × 80 mm, above JLCPCB's ≤100 × 100 mm price tier. Its L1 land was the 13 mm XAL1350 and its U7 land was SOT-23-5, but the BOM orders the 17.2 mm Sunlord MWSA1707S-100MT (C5240401) and the SC-70-5 TLV7011DCKR (C193688). Neither ordered part would have fit.

After: the board is 100 × 80 mm and re-routed, with 0 unconnected and 0 DRC errors (11 silk warnings). It is generated from the netlist, so L1 gets the schematic's 17 mm MWSA1707S/XAL1510 superset land and U7 gets SC-70-5. The 120 × 80 layout is kept on branch phase1-120x80.

How

• The input stage, bridge, controller, aux rails and MCU (everything left of x ≈ 64 mm) are unchanged.
• The output bank is tightened around the bigger L1. R27 (preload) moves to the top PGND strip.
• R30 (Kelvin shunt), U4, U5 and the Kelvin sense pair move as one block, so the sense geometry is unchanged.
• Q3/Q4 (back-to-back disconnect), J4 (output terminal) and U6 (LTC7004) stack down the right edge.
  • U6 now sits below the ground seam, so the AGND pocket is gone.
  • J4.2 (PGND) is joined solid to the ground planes, replacing its old via pair.
• The VOUT_INT feedback sense run (52 mm, tapped at L1.2) keeps at least 5.56 mm from SW copper on every layer.
  • Freerouting had first run it 0.25 mm past the SW island.
  • The new tools/fb_reroute.py re-routes it with SW copper, grown by 5.5 mm, as a keep-out.
• gen_board.py now checks real courtyard polygons, not bounding boxes. This removes 4 false overlaps the old check reported.
• The pipeline ran as in tools/README.md: pass 1, fanout.py, Freerouting 1.9, finish_routes.py, fb_reroute.py, silk and planes, then DRC.
• The fab zip, CPL and BOM were regenerated.
• The F1 BOM note now says the land is a direct-solder mini blade fuse (no holder), not C3207114.
• HANDOVER, MECHANICAL and the tools README are updated.

🤖 Generated with Claude Code

https://claude.ai/code/session_017ZrT5TjsLMQoxTZy1jabew