Error: Board has malformed outline (no edges found on Edge.Cuts layer)

DRC error points to a place far outside of the workspace. I have deleted all layers in that place, removed many parts thinking an attribute was assigned away from the part, redrawn the layer, updated to 7.0.5, all to no avail.

Also I redrew the board perimeter as a rectangle, separate lines, all on Edge.Cuts layer, the problem persists. The result of this error makes the 3D view look like this:


My next step if no suggestions work is to cut and paste the design into a new project file…if that works.
Thanks in advance for any ideas!

In desperation I zoomed all the way out to the -X limit at -2200 mm and still didn’t see anything, but did a select but nothing showed up, but cut everything to the left of the PCB anyway…and it cleared the error. The DRC arrow didn’t point to whatever it was, but there must have been something >1500 mm to the left of the workspace…Go figure.

without the project or at least the board file it is really hard to debug anything here. there probably was a very short section of line on Edge.Cuts somewhere to the left of your PCB which kicad could not interpret.

Back in V5 days, I once had a single pixel Edge Cuts glitch far outside the board.
I found like you did

While I’m glad to have fixed the error I am at a loss to figure out why any object could have been loaded so far outside of any view I ever did…and the error arrow pointed to a place some 1000 mm to the positive of it…
Perhaps a database glitch…
Thanks for replying all!

Cosmic rays are my ā€˜goto’ excuse for weird computer errors. :wink:

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I had similar problem when I started using Kicad. I discovered the problem was ā€˜me’.

When starting to draw my Edge-Cut with Mouse/Cursor not in the PCB visible area and had drawn only a Line short enough to be only a Dot (a Pixel) and that my Grid setting was too small such that the ā€˜short’ line was too small to see it.

How did I discover this? I opened the PCB file in a Text Editor and looked for the Edge-Cuts (and, in case of having drawn on another Layer, I looked at all the layer tags). I discovered I drew the line by error and was able to repeat it.

Zoomed-Image of your Error shows the Pixel at the end of the Arrow.
Screen Shot 2023-06-19 at 08.26.27

Below screenshot shows Example of a minimal-length line and it’s listing the the PCB file… I stopped foolishly clicking and made sure to pay attention…

Next two Images show a Single pixel (thus, zero-length) on Edge-Cut layer and the Code-text in the PCB file showing the line starts at Zero length and ends at Zero length.

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You have captured what I saw. Why these zero length segments are not rejected by the software is a question. They are certainly very hard to see on the screen and I cannot think of a need for them

Let’s say did or didn’t create that Pixel, either way, all you need to do is to ā€˜Delete it’.

You can Window-box it, and delete it.
If it’s in a PCB file created from a Template, then, open that Template File and delete the Pixel and Save the Template file.

I would be interested to know if ā€œCleanup Tracks and Viasā€ touches Edge Cuts glitches.
If it doesn’t we should raise an issue to try to get it added to 7.99

Some experimenting with 7.0.5 on Ubuntu finds some strange behaviour.

A line outside the board outline causes the 3D view to be extended to include it. DRC complains about the edge cuts outline and highlights the existence of this line.

A zero length line outside the outline is still visible as a pixel, but does not cause the 3D view to extend.
DRC gives no errors or warning.
The cleanup tool does nothing

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