Drogheda/03-Architecture-Hardware/kicad/RUN-usb-autoroute-README.md

USB/reset/LED autoroute — run on your Mac, then import the .ses

DSN: hbox-watchdog-v3-PROD-usb.dsn — the current 132-part board with your existing routing already in it (1069 wires) + the 9 new nets unrouted. So FreeRouting starts with "incomplete" ≈ the 9 new connections and should drive to 0 almost immediately — it's only routing USB_VBUS/DP/DM, USB_CC1/CC2, MODEM_RST, MODEM_LED(_A). GND rides the In1 plane.

Clearance 0.2 mm, width 0.2 mm (fine for these low-current USB/signal nets).

1. Route it

Headless (simplest):

cd "/Users/leo/Documents/Claude/Projects/Drogheda/03-Architecture-Hardware/kicad"
java -jar freerouting-1.9.0.jar \
  -de hbox-watchdog-v3-PROD-usb.dsn \
  -do hbox-watchdog-v3-PROD-usb.ses \
  -mp 30

Or GUI (more control): java -jar freerouting-1.9.0.jar → File → Open Design → hbox-watchdog-v3-PROD-usb.dsn → watch the incomplete count fall to 0 → File → Export Specctra Session File → hbox-watchdog-v3-PROD-usb.ses.

The DSN carries your existing traces, so FreeRouting mostly just fills in the 9 new nets. If you want to be conservative and let it touch the existing routing as little as possible, stop as soon as incomplete hits 0 (GUI) — no need to let it grind optimization passes.

2. Bring it back into KiCad

Open the board → File → Import → Specctra Session → hbox-watchdog-v3-PROD-usb.ses → press B to refill the In1 GND plane → Inspect → Design Rules Checker.

Paste me the DRC summary and I'll help clear anything real before you fab. Do not run F8 — the parts are already placed; you're only importing routing now.

3. Fab

Re-export the JLCPCB package (Gerbers + drill + BOM + CPL), order as 4-layer (F.Cu / In1 GND / In2.Cu / B.Cu, JLC 1.6 mm standard).