Add a min pin width advanced config for plotting.

Fixes https://gitlab.com/kicad/code/kicad/issues/5546

common/advanced_config.cpp

@@ -76,8 +76,8 @@ static const wxChar DRCEpsilon[] = wxT( "DRCEpsilon" );
 
 /**
  * Used to calculate the actual hole size from the finish hole size.
- * IPC-6012 says 15-18um; Cadence says at least 0.020 for a Class 2 board and at least 0.025
- * for Class 3.
+ * IPC-6012 says 0.015-0.018mm; Cadence says at least 0.020mm for a Class 2 board and at least
+ * 0.025mm for Class 3.
  */
 static const wxChar HoleWallThickness[] = wxT( "HoleWallPlatingThickness" );
 
@@ -132,6 +132,12 @@ static const wxChar StrokeTriangulation[] = wxT( "StrokeTriangulation" );
  */
 static const wxChar PluginAltiumSch[] = wxT( "PluginAltiumSch" );
 
+/**
+ * Absolute minimum pen width to send to the plotter.  PDF seems happy enough with 0.0212mm
+ * (which equates to 1px @ 1200dpi).
+ */
+static const wxChar MinPlotPenWidth[] = wxT( "MinPlotPenWidth" );
+
 } // namespace KEYS
 
 
@@ -217,13 +223,16 @@ ADVANCED_CFG::ADVANCED_CFG()
     m_DrawTriangulationOutlines = false;
     m_PluginAltiumSch           = false;
 
-    m_extraClearance            = 0.0005;
+    m_ExtraClearance            = 0.0005;
     m_DRCEpsilon                = 0.0005;   // 500nm is small enough not to materially violate
                                             // any constraints.
 
-    m_holeWallThickness         = 0.020;    // IPC-6012 says 15-18um; Cadence says at least
+    m_HoleWallThickness         = 0.020;    // IPC-6012 says 15-18um; Cadence says at least
                                             // 0.020 for a Class 2 board and at least 0.025
                                             // for Class 3.
+
+    m_MinPlotPenWidth           = 0.0212;   // 1 pixel at 1200dpi.
+
     loadFromConfigFile();
 }
 
@@ -265,13 +274,13 @@ void ADVANCED_CFG::loadSettings( wxConfigBase& aCfg )
                                                 &m_realTimeConnectivity, true ) );
 
     configParams.push_back( new PARAM_CFG_DOUBLE( true, AC_KEYS::ExtraFillMargin,
-                                                  &m_extraClearance, 0.0005, 0.0, 1.0 ) );
+                                                  &m_ExtraClearance, 0.0005, 0.0, 1.0 ) );
 
     configParams.push_back( new PARAM_CFG_DOUBLE( true, AC_KEYS::DRCEpsilon,
                                                   &m_DRCEpsilon, 0.0005, 0.0, 1.0 ) );
 
     configParams.push_back( new PARAM_CFG_DOUBLE( true, AC_KEYS::HoleWallThickness,
-                                                  &m_holeWallThickness, 0.020, 0.0, 1.0 ) );
+                                                  &m_HoleWallThickness, 0.020, 0.0, 1.0 ) );
 
     configParams.push_back( new PARAM_CFG_INT( true, AC_KEYS::CoroutineStackSize,
                                                &m_coroutineStackSize, AC_STACK::default_stack,
@@ -295,6 +304,9 @@ void ADVANCED_CFG::loadSettings( wxConfigBase& aCfg )
     configParams.push_back( new PARAM_CFG_BOOL( true, AC_KEYS::PluginAltiumSch,
                                                 &m_PluginAltiumSch, false ) );
 
+    configParams.push_back( new PARAM_CFG_DOUBLE( true, AC_KEYS::MinPlotPenWidth,
+                                                  &m_MinPlotPenWidth, 0.0212, 0.0, 1.0 ) );
+
     wxConfigLoadSetups( &aCfg, configParams );
 
     for( PARAM_CFG* param : configParams )

common/render_settings.cpp

@@ -39,6 +39,7 @@ RENDER_SETTINGS::RENDER_SETTINGS() :
     m_outlineWidth       = 1;
     m_worksheetLineWidth = 100000;
     m_defaultPenWidth    = 0;
+    m_minPenWidth        = 0;
     m_showPageLimits     = false;
 }
 

eeschema/lib_arc.cpp

@@ -275,7 +275,7 @@ void LIB_ARC::Plot( PLOTTER* aPlotter, const wxPoint& aOffset, bool aFill,
 
     if( !already_filled || pen_size > 0 )
     {
-        pen_size = std::max( pen_size, aPlotter->RenderSettings()->GetDefaultPenWidth() );
+        pen_size = std::max( pen_size, aPlotter->RenderSettings()->GetMinPenWidth() );
 
         aPlotter->SetColor( aPlotter->RenderSettings()->GetLayerColor( LAYER_DEVICE ) );
         aPlotter->Arc( pos, -t2, -t1, m_Radius, already_filled ? NO_FILL : m_Fill, pen_size );

eeschema/lib_bezier.cpp

@@ -187,7 +187,7 @@ void LIB_BEZIER::Plot( PLOTTER* aPlotter, const wxPoint& aOffset, bool aFill,
 
     if( !already_filled || pen_size > 0 )
     {
-        pen_size = std::max( pen_size, aPlotter->RenderSettings()->GetDefaultPenWidth() );
+        pen_size = std::max( pen_size, aPlotter->RenderSettings()->GetMinPenWidth() );
 
         aPlotter->SetColor( aPlotter->RenderSettings()->GetLayerColor( LAYER_DEVICE ) );
         aPlotter->PlotPoly( cornerList, already_filled ? NO_FILL : m_Fill, pen_size );

eeschema/lib_circle.cpp

@@ -178,7 +178,7 @@ void LIB_CIRCLE::Plot( PLOTTER* aPlotter, const wxPoint& aOffset, bool aFill,
 
     if( !already_filled || pen_size > 0 )
     {
-        pen_size = std::max( pen_size, aPlotter->RenderSettings()->GetDefaultPenWidth() );
+        pen_size = std::max( pen_size, aPlotter->RenderSettings()->GetMinPenWidth() );
 
         aPlotter->SetColor( aPlotter->RenderSettings()->GetLayerColor( LAYER_DEVICE ) );
         aPlotter->Circle( pos, GetRadius() * 2, already_filled ? NO_FILL : m_Fill, pen_size );

eeschema/lib_field.cpp

@@ -288,7 +288,7 @@ void LIB_FIELD::Plot( PLOTTER* aPlotter, const wxPoint& aOffset, bool aFill,
     else
         color = COLOR4D::BLACK;
 
-    int penWidth = std::max( GetPenWidth(),aPlotter->RenderSettings()->GetDefaultPenWidth() );
+    int penWidth = std::max( GetPenWidth(),aPlotter->RenderSettings()->GetMinPenWidth() );
 
     aPlotter->Text( textpos, color, GetShownText(), orient, GetTextSize(), hjustify, vjustify,
                     penWidth, IsItalic(), IsBold() );

eeschema/lib_rectangle.cpp

@@ -144,7 +144,7 @@ void LIB_RECTANGLE::Plot( PLOTTER* aPlotter, const wxPoint& aOffset, bool aFill,
 
     if( !already_filled || pen_size > 0 )
     {
-        pen_size = std::max( pen_size, aPlotter->RenderSettings()->GetDefaultPenWidth() );
+        pen_size = std::max( pen_size, aPlotter->RenderSettings()->GetMinPenWidth() );
 
         aPlotter->SetColor( aPlotter->RenderSettings()->GetLayerColor( LAYER_DEVICE ) );
         aPlotter->Rect( pos, end, already_filled ? NO_FILL : m_Fill, pen_size );

eeschema/lib_text.cpp

@@ -287,8 +287,9 @@ void LIB_TEXT::Plot( PLOTTER* plotter, const wxPoint& offset, bool fill,
     else
         color = COLOR4D::BLACK;
 
-    int penWidth = std::max( GetEffectiveTextPenWidth(),
-                             plotter->RenderSettings()->GetDefaultPenWidth() );
+    RENDER_SETTINGS* settings = plotter->RenderSettings();
+
+    int penWidth = std::max( GetEffectiveTextPenWidth(), settings->GetMinPenWidth() );
 
     plotter->Text( pos, color, GetText(), t1 ? TEXT_ANGLE_HORIZ : TEXT_ANGLE_VERT, GetTextSize(),
                    GR_TEXT_HJUSTIFY_CENTER, GR_TEXT_VJUSTIFY_CENTER, penWidth, IsItalic(),

eeschema/sch_bus_entry.cpp

@@ -395,6 +395,8 @@ void SCH_BUS_ENTRY_BASE::Plot( PLOTTER* aPlotter )
             settings->GetLayerColor( m_Layer ) : GetStrokeColor();
     int     penWidth = ( GetPenWidth() == 0 ) ? settings->GetDefaultPenWidth() : GetPenWidth();
 
+    penWidth = std::max( penWidth, settings->GetMinPenWidth() );
+
     aPlotter->SetCurrentLineWidth( penWidth );
     aPlotter->SetColor( color );
     aPlotter->SetDash( GetStrokeStyle() );

eeschema/sch_field.cpp

@@ -526,9 +526,11 @@ bool SCH_FIELD::HitTest( const EDA_RECT& aRect, bool aContained, int aAccuracy )
 
 void SCH_FIELD::Plot( PLOTTER* aPlotter )
 {
-    COLOR4D color = aPlotter->RenderSettings()->GetLayerColor( GetLayer() );
-    int     penWidth = GetEffectiveTextPenWidth(
-                            aPlotter->RenderSettings()->GetDefaultPenWidth() );
+    RENDER_SETTINGS* settings = aPlotter->RenderSettings();
+    COLOR4D          color = settings->GetLayerColor( GetLayer() );
+    int              penWidth = GetEffectiveTextPenWidth( settings->GetDefaultPenWidth() );
+
+    penWidth = std::max( penWidth, settings->GetMinPenWidth() );
 
     if( !IsVisible() )
         return;

eeschema/sch_line.cpp

@@ -749,11 +749,11 @@ void SCH_LINE::Plot( PLOTTER* aPlotter )
     default:         penWidth = GetPenWidth();                    break;
     }
 
-    penWidth = std::max( penWidth, aPlotter->RenderSettings()->GetDefaultPenWidth() );
-
     if( m_stroke.GetWidth() != 0 )
         penWidth = m_stroke.GetWidth();
 
+    penWidth = std::max( penWidth, settings->GetMinPenWidth() );
+
     aPlotter->SetCurrentLineWidth( penWidth );
     aPlotter->SetDash( GetEffectiveLineStyle() );
 

eeschema/sch_no_connect.cpp

@@ -177,7 +177,7 @@ void SCH_NO_CONNECT::Plot( PLOTTER* aPlotter )
     int delta = GetSize() / 2;
     int pX = m_pos.x;
     int pY = m_pos.y;
-    int penWidth = std::max( GetPenWidth(), aPlotter->RenderSettings()->GetDefaultPenWidth() );
+    int penWidth = std::max( GetPenWidth(), aPlotter->RenderSettings()->GetMinPenWidth() );
 
     aPlotter->SetCurrentLineWidth( penWidth );
     aPlotter->SetColor( aPlotter->RenderSettings()->GetLayerColor( LAYER_NOCONNECT ) );

eeschema/sch_painter.cpp

@@ -62,6 +62,7 @@
 #include <view/view.h>
 #include <kiface_i.h>
 #include <default_values.h>
+#include <advanced_config.h>
 #include "sch_painter.h"
 
 namespace KIGFX
@@ -83,6 +84,8 @@ SCH_RENDER_SETTINGS::SCH_RENDER_SETTINGS() :
         m_JunctionSize( DEFAULT_JUNCTION_DIAM * IU_PER_MILS )
 {
     SetDefaultPenWidth( DEFAULT_LINE_THICKNESS * IU_PER_MILS );
+
+    m_minPenWidth = ADVANCED_CFG::GetCfg().m_MinPlotPenWidth * IU_PER_MM;
 }
 
 

eeschema/sch_sheet.cpp

@@ -966,7 +966,7 @@ void SCH_SHEET::Plot( PLOTTER* aPlotter )
 
     aPlotter->SetColor( borderColor );
 
-    int penWidth = std::max( GetPenWidth(), aPlotter->RenderSettings()->GetDefaultPenWidth() );
+    int penWidth = std::max( GetPenWidth(), aPlotter->RenderSettings()->GetMinPenWidth() );
     aPlotter->SetCurrentLineWidth( penWidth );
 
     aPlotter->MoveTo( m_pos );

eeschema/sch_text.cpp

@@ -581,6 +581,7 @@ void SCH_TEXT::Plot( PLOTTER* aPlotter )
     COLOR4D color = aPlotter->RenderSettings()->GetLayerColor( GetLayer() );
     int penWidth = GetEffectiveTextPenWidth( aPlotter->RenderSettings()->GetDefaultPenWidth() );
 
+    penWidth = std::max( penWidth, aPlotter->RenderSettings()->GetMinPenWidth() );
     aPlotter->SetCurrentLineWidth( penWidth );
 
     if( IsMultilineAllowed() )

include/advanced_config.h

@@ -84,20 +84,21 @@ public:
 
     /**
      * Extra fill clearance for zone fills.  Note that for zone tests this is essentially
-     * additive with m_DRCEpsilon.
+     * additive with m_DRCEpsilon.  Units are mm.
      */
-    double m_extraClearance;
+    double m_ExtraClearance;
 
     /**
      * Epsilon for DRC tests.  Note that for zone tests this is essentially additive with
-     * m_extraClearance.
+     * m_extraClearance.  Units are mm.
      */
     double m_DRCEpsilon;
 
     /**
      * Hole wall plating thickness.  Used to determine actual hole size from finish hole size.
+     * Units are mm.
      */
-    double m_holeWallThickness;
+    double m_HoleWallThickness;
 
     /**
      * Do real-time connectivity
@@ -131,6 +132,12 @@ public:
      */
     bool m_PluginAltiumSch;
 
+    /**
+     * Sets an absolute minimum pen width for plotting.  Some formats (PDF, for example) don't
+     * like ultra-thin lines.  Units are mm.
+     */
+    double m_MinPlotPenWidth;
+
 private:
     ADVANCED_CFG();
 

include/render_settings.h

@@ -164,6 +164,9 @@ public:
     int GetDefaultPenWidth() const { return m_defaultPenWidth; }
     void SetDefaultPenWidth( int aWidth ) { m_defaultPenWidth = aWidth; }
 
+    int GetMinPenWidth() const { return m_minPenWidth; }
+    void SetMinPenWidth( int aWidth ) { m_minPenWidth = aWidth; }
+
     bool GetShowPageLimits() const { return m_showPageLimits; }
     void SetShowPageLimits( bool aDraw ) { m_showPageLimits = aDraw; }
 
@@ -268,6 +271,8 @@ protected:
     float         m_worksheetLineWidth;   // Line width used when drawing worksheet
 
     int           m_defaultPenWidth;
+    int           m_minPenWidth;          // Some clients (such as PDF) don't like ultra-thin
+                                          // lines.  This sets an absolute minimum.
     bool          m_showPageLimits;
 
     wxDC*         m_printDC;              // This can go away once we have Cairo-based printing.

pcbnew/board_design_settings.cpp

@@ -969,7 +969,7 @@ int BOARD_DESIGN_SETTINGS::GetDRCEpsilon() const
 
 int BOARD_DESIGN_SETTINGS::GetHolePlatingThickness() const
 {
-    return Millimeter2iu( ADVANCED_CFG::GetCfg().m_holeWallThickness );
+    return Millimeter2iu( ADVANCED_CFG::GetCfg().m_HoleWallThickness );
 }
 
 

pcbnew/zone_filler.cpp

@@ -601,7 +601,7 @@ void ZONE_FILLER::buildCopperItemClearances( const ZONE_CONTAINER* aZone, PCB_LA
     // requested clearance due to many approximations in calculations, like arc to segment
     // approx, rounding issues, etc.
     // 1 micron is a good value
-    int extra_margin = Millimeter2iu( ADVANCED_CFG::GetCfg().m_extraClearance );
+    int extra_margin = Millimeter2iu( ADVANCED_CFG::GetCfg().m_ExtraClearance );
 
     BOARD_DESIGN_SETTINGS& bds = m_board->GetDesignSettings();
     int                    zone_clearance = aZone->GetLocalClearance();