Hi. I’m currently working to convert some KiCad 5 projects to KiCad 6. I’ve been running into the problem that whenever I convert my files, the fill zones extend closer to the edge of the PCB than on the original boards. Below are two images of the same board. The second image was taken immediately after converting the PCB and refilling all zones. As far as I can tell, no settings were changed. Both fill zones have a clearance of 12 mils, but in the converted project the fill zone is only 9 mils from the edge.
So far, I have tried to edit the copper zone properties to increase the clearance. That corrected the edges of the fill zone, but also increased the distance between traces and the fill zone. I have also attempted to edit the copper to edge clearance in design rules, but not all of my fill zones are intended to be the same distance from the edge.
Has anyone else come across this problem and found a solution to it?
The edge of the board is the center of the Edge.Cuts line, not the edge of the line. What happens if you measure to the center of the line?
I suspect the difference is that the default thickness of the Edge.Cuts line changed between v5 and v6, so converted boards have a different line thickness than new boards. This has no physical effect on manufactured boards, it only affects how they appear in software.
In KiCad V5 (Or was it V4?) the lines on Edge.Cuts were treated as tracks, and the clearance was calculated from the edge of the track, and making the lines on Edge.Cuts thicker did indeed also make the clearance bigger.
In KiCad V6 you can set this clearance in PCB Editor / File / Board Setup / Design Rules / Constraints / Copper to edge clearance, and it follows the default rules, so it takes the biggest clearance of either this, or the clearance defined in a zone itself.
