Move board-config/title-block patching to Rust

[akhilles]

Note

Medium Risk
Changes affect deterministic generation and mutation of .kicad_pcb/.kicad_pro during layout sync, which could introduce formatting or settings drift across KiCad versions and existing projects despite added idempotency tests.

Overview
Moves KiCad board/project configuration patching out of the Python sync step and into Rust.

Layout sync now post-processes both .kicad_pcb and .kicad_pro: the PCB file is structurally patched and prettified to enforce a canonical title_block (with ${PCB_NAME}/${CURRENT_DATE}/${PCB_VERSION}) and to apply stackup/layer/thickness updates; the project file is patched via a new Rust kicad_project_patch module that idempotently upserts constraint fields, predefined track/via sizes (merging without deleting user entries), netclasses, and only netclass pattern assignments when such assignments exist.

Python update_layout_file.py is simplified by removing the SetupBoard/--board-config path and related orphan-cleanup logic, and pcb layout --check now also detects drift in the generated .kicad_pro in addition to the PCB file; release test suppression is updated accordingly.

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[cursor]

Missing project file now aborts layout sync

Medium Severity

process_layout now always calls patch_project_file whenever board_config exists. patch_kicad_pro immediately reads *.kicad_pro, so runs fail if that file is missing. Since resolve_kicad_files can return a default path for non-existent projects and update_layout_file.py only creates *.kicad_pcb, fresh layouts with board_config can error out.

Additional Locations (1)

• crates/pcb-layout/src/kicad_project_patch.rs#L73-L76

 

[cursor]

Cursor Bugbot has reviewed your changes and found 1 potential issue.

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