Thermal relief connection to zone incomplete (layer In1.Cu; 5 spokes connected to isolated island)

Hi. I’m getting the error

“Thermal relief connection to zone incomplete (layer In1.Cu; 5 spokes connected to isolated island)”

Minimum thermal relief spoke count is set to 2.

This is a ground plane with a single connection to ground. All other potential connections to ground are excluded using “Keep out zone fills”.

I can’t find an island and I can’t find a fifth spoke. Changing Pad Connections to solid gets rid of the error. I have an identical (I think) ground plane on In2 and there’s no problem there.

I don’t know whether it will help, but here is a screenshot:

Any suggestions much appreciated!

The whole plane is an island.

With a simple test (1 net GND, 1 zone for that net, 2 1-pad footprints for that net where 1 footprint/pad is isolated with keepout area) I can’t get that message. So, there may be something else going on.

What is the zone property “Remove islands”? Set it to Always if it’s not already, and re-fill. Does something else happen?

Often the simplest way to get help is to upload the zipped (but cleaned up) project here. That way we don’t have to guess and go on with back and forth questions and answers.

Thanks. “Remove Islands” is indeed set to “Always”. Here’s the zip file.

JLPCB are adding a $24 Engineering Fee to the quoted despite the Board Setup and Constraints being the same as many other boards I’ve had manufactured. Maybe that’s related to this problem.

LLC resonant half-bridge converter multiple outputs.zip (370.9 KB)

I can replicate. V9.0.7RC1 Win10. Odd. Smells bug like. As a workaround, if you add a short route segment into the zone overlapping the alleged 5th spoke? then refill and rerun DRC, that error clears.

Thanks Dave!

Rgds, Dave.