KiCAD Design Review & Validation Workflow

This skill guides Claude through systematic design review of a KiCAD project using MCP tools. ALL checks are performed through MCP tools — never parse .kicad_sch or .kicad_pcb files directly.

---

Toolset Loading

Load the required toolsets for design review:

load_toolset('sch_analysis')     # find_orphan_items, find_shorted_nets, find_single_pin_nets
load_toolset('verification')     # run_drc, check_clearance, get_design_rules
load_toolset('sch_export')       # run_erc
load_toolset('pcb_export')       # get_drc_violations
load_toolset('manufacturing')    # validate_for_manufacturing
load_toolset('design_review')    # audit_decoupling, audit_connections, audit_power_rails, etc.

Optional (for deeper analysis):

load_toolset('sch_analysis')     # get net info, trace connections, inspect components
load_toolset('pcb_routing')      # query_traces, get_nets_list

Always call get_active_toolsets() first to see what is already loaded.

Evidence hierarchy

Judge findings in this order:

1. Exact design requirements and manufacturer datasheets.
2. Direct KiCad ERC/DRC and saved or exported connectivity.
3. Direct Konnect net, short, pad, trace, via, unrouted, and inventory evidence.
4. Aggregate review and manufacturing summaries.
5. Heuristic orphan, single-pin, decoupling, protection, and best-practice findings.

A weaker finding may ask a question; it does not override stronger contradictory evidence. Any required check that did not run, returned impossible coverage, or remains inconsistent with stronger evidence makes the verdict INCOMPLETE.

References by review branch

• Read references/design-checklist.md for a comprehensive or pre-fabrication review. Mark an item only from evidence collected in this run.
• Read references/error-taxonomy.md when classifying a finding or assigning the final verdict. Direct ERC, DRC, and connectivity evidence outrank heuristic classifications.

---

Quick Checks (Escalating Severity)

Run these first — they are fast and catch the most critical issues.

Level 1: Structural Integrity

find_orphan_items()

Finds floating wires, labels, and symbols not connected to anything. Treat the result as a heuristic candidate list and corroborate it with direct connectivity or ERC before calling an item a defect.

Level 2: Critical Net Issues

find_shorted_nets()

Detects nets that are connected together but should not be. A shorted net means:

• Two different net labels on the same wire
• Power rails bridged unintentionally
• Signal nets merged by accident

A confirmed unintended short is critical. Resolve disagreement with requirements or direct ERC/connectivity evidence before assigning severity.

Level 3: Suspicious Connections

find_single_pin_nets()

A one-pin net is a heuristic review candidate:

• Incomplete wiring (forgot to connect the other end)
• Orphan net labels (typo in name, so it does not match)
• Leftover stubs from deleted components

---

Formal Checks

ERC — Electrical Rules Check

run_erc()

Checks schematic-level rules:

• Pin type conflicts (output driving output, unconnected inputs)
• Power pin connections
• Missing no-connect flags
• Duplicate reference designators
• Missing net connections

Review each violation. Some can be waived (e.g., intentional unconnected pins marked with no-connect flag).

DRC — Design Rules Check

get_drc_violations()

Checks PCB-level rules:

• Clearance violations (copper-to-copper, copper-to-edge)
• Minimum trace width violations
• Minimum drill size violations
• Unrouted connections (incomplete routing)
• Zone fill issues
• Courtyard overlaps

Every DRC error must be resolved or explicitly justified before manufacturing.

---

Design Audits

These go beyond rule checking — they evaluate design quality and best practices.

The standalone schematic audits and check_bom_health default to the supplied file only. When the supplied file is a hierarchy root, pass schematic_scope: "hierarchy" to cover every reachable sheet instance. Read status, coverage, and diagnostics before interpreting a hierarchy result; missing or cyclic child references make the result incomplete. Reused child files have one result per KiCad sheet instance, identified by the sheet_instance_path response field.

Decoupling Audit

audit_decoupling(schematic, schematic_scope="hierarchy")

Checks:

• Every IC power pin has a bypass capacitor
• Capacitor is placed close to the pin (PCB proximity)
• Appropriate capacitor values (100nF ceramic minimum)
• Bulk capacitance present for high-current ICs

Connection Audit

audit_connections(schematic, schematic_scope="hierarchy")

Checks:

• All expected connections are made
• No nets with unexpected fan-out
• Signal integrity basics (termination on long traces)
• Pull-up/pull-down resistors where required (I2C, reset pins, enable pins)

Power Rail Audit

audit_power_rails(schematic, schematic_scope="hierarchy")

Checks:

• All power rails have proper source (regulator, connector, etc.)
• Current capacity matches expected load
• Voltage levels are consistent (no 3.3V device on 5V rail)
• Power sequencing considered for multi-rail designs
• Power flags present (avoids ERC false positives)

Manufacturing Audit

audit_manufacturing()

Checks:

• All footprints are fab-house compatible
• Pad sizes meet minimum requirements
• Silkscreen readability
• Test point accessibility
• Fiducial marks present (for SMT assembly)
• Mechanical clearances around mounting holes

---

Full Review Shortcut

run_design_review()

Runs the aggregate design audits and produces a consolidated report. Use it to organize findings, not as a substitute for the direct ERC, DRC, and connectivity checks above.

Read status, coverage, and diagnostics before interpreting the findings. If status is partial or failed, the verdict is INCOMPLETE — review could not evaluate the full design. Report that verdict verbatim, explain the diagnostics and unevaluated coverage, and do not describe the design as ready, passing, clean, or looking good. Findings gathered before the coverage gap are still valid and should still be reported.

Collect direct run_erc, get_drc_violations, short, and connectivity evidence separately. Then compare the aggregate findings with that stronger evidence and report any disagreement.

---

Severity Classification

CRITICAL — Must fix before manufacturing

Finding	Why Critical
Shorted nets	Short circuit on the board, may damage components
Missing ground connection	Circuit will not function
Reversed polarity on power IC	Immediate destruction on power-up
Unrouted nets	Missing connections on fabricated board
DRC clearance violation	May cause electrical short on fab board
Power pin unconnected	IC will not operate
Wrong voltage on IC power pin	Exceeds absolute maximum, destroys part

WARNING — Should fix, design risk

Finding	Why a Warning
Missing decoupling capacitor	Noise susceptibility, possible oscillation
No test points on key signals	Cannot debug in production
No ESD protection on connectors	Vulnerable to ESD damage in the field
Single-point-of-failure nets	No redundancy for critical signals
Pull-up/pull-down missing	Floating input, unpredictable behavior
Tight clearances (near DRC limit)	Higher fab defect rate

SUGGESTION — Improvement opportunities

Finding	Why a Suggestion
Consolidate passive values	Fewer unique BOM lines, lower assembly cost
Add net labels to unnamed nets	Improves schematic readability
Missing silkscreen designators	Harder to assemble and debug manually
Components could be closer	Shorter traces, better signal integrity
Consider bulk capacitor addition	Better transient response on power rails
Add board revision marking	Traceability for manufacturing runs

---

Reporting Format

Present findings grouped by severity with actionable fix suggestions:

## Design Review Results

### CRITICAL (X issues) — Must fix

1. **[Finding title]**
   - Location: [component reference or net name]
   - Issue: [what is wrong]
   - Fix: [specific action to take using MCP tools]

### WARNING (X issues) — Should fix

1. **[Finding title]**
   - Location: [component reference or net name]
   - Issue: [what is wrong]
   - Fix: [specific action to take]

### SUGGESTION (X items) — Optional improvements

1. **[Finding title]**
   - Detail: [what could be better]
   - Action: [suggested improvement]

### Summary
- Critical: X (must resolve)
- Warnings: X (recommended)
- Suggestions: X (optional)
- Verdict: [LOOKS GOOD / NEEDS ATTENTION / NOT READY / INCOMPLETE]
- Coverage status: [complete / partial / failed]
- Coverage diagnostics: [none, or each unevaluated sheet/object/audit]

---

Review Workflow

Quick Review (5-minute check)

1. find_shorted_nets() — catch fatal issues
2. run_erc() — schematic rule check
3. get_drc_violations() — PCB rule check
4. Report findings

Full Review (comprehensive)

1. Load all review toolsets
2. Run direct short/connectivity checks, run_erc, and get_drc_violations
3. run_design_review() — aggregate audit suite
4. Check status, coverage, and diagnostics; never approve an incomplete review
5. Reconcile aggregate or heuristic findings with stronger direct evidence
6. Classify all gathered findings by severity
7. Present report with fix suggestions
8. Offer to fix CRITICAL issues immediately

Pre-Manufacturing Review

1. Full review (above)
2. Run validate_for_manufacturing(), then inspect verdict, issues, and drc against the handler's limited contract; it does not replace outline, drill, silkscreen, artifact, BOM/CPL, or order-preview acceptance
3. Verify BOM completeness
4. Check part availability (if targeting specific fab house)
5. Final verdict: ready to manufacture or not

---

Rules

1. Never skip quick checks — find_shorted_nets catches the worst bugs fast
2. Classify every finding — severity helps the user prioritize
3. Provide specific fixes — name the MCP tool and parameters to resolve each issue
4. Run DRC after fixes — verify that corrections did not introduce new violations
5. Do not approve a design with CRITICAL issues — even if the user says "it's fine"
6. Load toolsets first — check get_active_toolsets() and load what you need
7. Save before reviewing — ensures checks run against current state
8. Offer to fix — after reporting, offer to use MCP tools to resolve issues
9. Re-run after fixes — always verify fixes resolved the issue and created no new ones
10. Document waivers — if user explicitly waives a warning, note it in the report
11. Never soften INCOMPLETE — partial or failed coverage is not a passing review