Board Outline becomes malformed without touching it

Hi,

I’m currently working on a grid shape board with cutouts. I stumbled a lot over malformed outlines during the creation of the board outline. I also tried to reproduce the issue but can’t do by intent. Finally I made it and started routing. I checked the outline several times by just using 3D view and suddenly, without any changes to the edge.cut layer, the board outline became malformed again.


I tried “Tools->CleanUp Graphics->Fix discontinuities 0.1mm” without success.

I restored a working version from the backup folder.
Note: I deleted everything but the edge.cut to protect IP of my customer.

Working:
Matrix_MalformedOutline_Before.kicad_pcb (460.5 KB)

Broken:
Matrix_MalformedOutline_After.kicad_pcb (631.8 KB)

Version Info

Application: KiCad PCB Editor x86_64 on x86_64

Version: 9.0.2, release build

Libraries:
wxWidgets 3.2.8
FreeType 2.13.3
HarfBuzz 9.0.0
FontConfig 2.15.0
libcurl/8.13.0 OpenSSL/3.3.3 zlib/1.3.1 libidn2/2.3.7 libpsl/0.21.5 nghttp2/1.65.0

Platform: Freedesktop SDK 24.08 (Flatpak runtime), 64 bit, Little endian, wxGTK, X11, KDE (One-Time Launch), x11
OpenGL: AMD, AMD Custom GPU 0405 (radeonsi, vangogh, LLVM 19.1.7, DRM 3.59, 6.11.11-valve12-1-neptune-611-g517a46b477e1), 4.6 (Compatibility Profile) Mesa 25.0.5 (git-a89e404408)

Build Info:
Date: May 7 2025 04:22:22
wxWidgets: 3.2.8 (wchar_t,wx containers) GTK+ 3.24
Boost: 1.88.0
OCC: 7.9.0
Curl: 8.13.0
ngspice: 44.2
Compiler: GCC 14.2.0 with C++ ABI 1019
KICAD_IPC_API=ON

Locale:
Lang:
Enc: ANSI_X3.4-1968
Num: 1234.5
Encoded кΩ丈: (sys), D0BACEA9E4B888 (utf8)

Thanks in advance
David

You should also paste the version info into a preformatted text area.

Help > About KiCad > Copy Version Info, to get the info.

1 Like

You have duplicate lines . . .

. . . probably as a result of a DXF import ? I’ve had it before.

Oh ok. I used the „replicate Layout tool“ maybe I accidentally grouped some lines with the items to replicate.
Thanks!

In some places you have triplicates overlapping . . . and sometimes 5

image