Integrate Measured ESP32 PCB Geometry

- Add measured F.Fab bounds and USB mouth markers
- Add guarded preservation and regression validation
- Refresh review exports and remove draft presentation labels

hardware/PCB/add_device_silkscreen.py

@@ -10,6 +10,7 @@ import uuid
 import pcbnew as p
 from shapely.geometry import LineString, Point, box
 from shapely.ops import unary_union, polygonize
+from update_u1_graphics import verify
 
 ROOT = Path(__file__).resolve().parent
 PCB = ROOT / "serial-carrier.kicad_pcb"
@@ -38,6 +39,7 @@ def outline_lines(shape):
 
 
 def add_outlines(board):
+    verify(board)
     owned = {str(uuid.uuid5(NS, str(i))) for i in range(4096)}
     for drawing in list(board.GetDrawings()):
         if drawing.m_Uuid.AsString() in owned:
@@ -82,8 +84,11 @@ def add_outlines(board):
         board.Add(shape)
         count+=1
 
-    def line(a,b):
-        clipped=LineString([a,b]).intersection(silk_area).difference(blocked)
+    def line(a,b,width=WIDTH):
+        extra = max(0, (width-WIDTH)/2)
+        area = silk_area.buffer(-extra) if extra else silk_area
+        obstacles = blocked.buffer(extra) if extra else blocked
+        clipped=LineString([a,b]).intersection(area).difference(obstacles)
         pieces=list(clipped.geoms) if hasattr(clipped,"geoms") else [clipped]
         for piece in pieces:
             if piece.geom_type!="LineString" or piece.length < 0.25:
@@ -91,7 +96,7 @@ def add_outlines(board):
             shape=p.PCB_SHAPE(board)
             shape.SetShape(p.SHAPE_T_SEGMENT)
             shape.SetStart(vec(piece.coords[0])); shape.SetEnd(vec(piece.coords[-1]))
-            shape.SetWidth(p.FromMM(WIDTH))
+            shape.SetWidth(p.FromMM(width))
             add(shape)
 
     for ref in ("DS1","U2"):
@@ -137,22 +142,19 @@ def add_outlines(board):
                         distance+=1.3
                 else:
                     line(edge.coords[0],edge.coords[-1])
-    # These are pad-row guides, not inferred socket/body or ESP32 PCB dimensions.
-    fp=footprints["U1"]
-    assert fp.GetOrientationDegrees()==0, "Review guide construction for rotated U1"
-    pads={pad.GetNumber():xy(pad.GetPosition()) for pad in fp.Pads()}
-    for first,last in (("1","22"),("23","44")):
-        x,ytop=pads[first]; _,ybottom=pads[last]
-        corners=[(x-1.2,ytop-1.2),(x+1.2,ytop-1.2),(x+1.2,ybottom+1.2),(x-1.2,ybottom+1.2)]
-        for a,b in zip(corners,corners[1:]+corners[:1]):
-            line(a,b)
-    label=p.PCB_TEXT(board)
-    label.SetText("HEADER GUIDES")
-    a,b=pads["1"],pads["23"]
-    label.SetPosition(vec(((a[0]+b[0])/2,a[1]+28)))
-    label.SetTextSize(p.VECTOR2I(p.FromMM(0.85),p.FromMM(0.85)))
-    label.SetTextThickness(p.FromMM(0.12))
-    add(label)
+    # Union removes the shared body/antenna edge duplication. Mouth spans replace
+    # the coincident bottom-edge strokes, with their measured library line weight;
+    # this marks width only, without inventing connector depth or an RF keepout.
+    sources=[g for g in footprints["U1"].GraphicalItems()
+             if isinstance(g,p.PCB_SHAPE) and g.GetLayer()==p.F_Fab]
+    mouths=[g for g in sources if g.GetShape()==p.SHAPE_T_SEGMENT]
+    mouth_lines=unary_union([edge for g in mouths for edge in outline_lines(g)])
+    perimeter=unary_union([edge for g in sources if g.GetShape()==p.SHAPE_T_RECT
+                          for edge in outline_lines(g)]).difference(mouth_lines)
+    for edge in perimeter.geoms:
+        line(edge.coords[0],edge.coords[-1])
+    for mouth in mouths:
+        line(xy(mouth.GetStart()),xy(mouth.GetEnd()),p.ToMM(mouth.GetWidth()))
     return count