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Commit b4f26925 causes panelization to crash on Mac #875

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Commit b4f26925 causes panelization to crash on Mac#875
@mairas

Description

@mairas
mairas
opened on Dec 1, 2025

Prerequisites

  • I have read FAQ
  • I have searched existing issues (including closed ones)
  • I use KiKit at least version 1.7.2 (older version are not supported)

KiKit version

python -m kikit.ui, version 1.7.2+18.gb4f2692

KiCAD version (only KiCAD 8 and 9 are supported)

Version 9.0.6, release build

Operating system

MacOS 26.1

Description

This panelization command:

kikit panelize \
    --tabs 'annotation' \
    --framing 'frame; width: 5mm; space: 2mm' \
    --tooling '4hole; hoffset: 20mm; voffset: 3.5mm; size: 1.152mm' \
    --fiducials '4fid; hoffset: 30mm; voffset: 4mm; coppersize: 1mm; opening: 2mm;' \
    --layout 'grid; rows: 4; cols: 1; space: 5mm' \
    --cuts 'vcuts; layer: Edge.Cuts' \
    --post 'millradius: 2mm' \
    ${BOARD}.kicad_pcb ${BOARD}-panel.kicad_pcb

on this project: https://github.com/hatlabs/SH-ESP32-hardware (can provide an exact project archive on request)

results in KiKit crashing hard:

@cutter:~/w/h/S/SH-ESP32-hardware (v2.2.2|%) $ ./prepare_panel_assembly_vcuts.sh
Panelizing...
11:48:42 AM: Debug: Adding duplicate image handler for 'PNG file'
11:48:42 AM: Debug: Adding duplicate image handler for 'JPEG file'
11:48:42 AM: Debug: Adding duplicate image handler for 'TIFF file'
11:48:42 AM: Debug: Adding duplicate image handler for 'GIF file'
11:48:42 AM: Debug: Adding duplicate image handler for 'PNM file'
11:48:42 AM: Debug: Adding duplicate image handler for 'PCX file'
11:48:42 AM: Debug: Adding duplicate image handler for 'IFF file'
11:48:42 AM: Debug: Adding duplicate image handler for 'Windows icon file'
11:48:42 AM: Debug: Adding duplicate image handler for 'Windows cursor file'
11:48:42 AM: Debug: Adding duplicate image handler for 'Windows animated cursor file'
11:48:42 AM: Debug: Adding duplicate image handler for 'TGA file'
11:48:42 AM: Debug: Adding duplicate image handler for 'XPM file'
11:48:43 AM: Debug: Adding duplicate image handler for 'PNG file'
11:48:43 AM: Debug: Adding duplicate image handler for 'JPEG file'
11:48:43 AM: Debug: Adding duplicate image handler for 'TIFF file'
11:48:43 AM: Debug: Adding duplicate image handler for 'GIF file'
11:48:43 AM: Debug: Adding duplicate image handler for 'PNM file'
11:48:43 AM: Debug: Adding duplicate image handler for 'PCX file'
11:48:43 AM: Debug: Adding duplicate image handler for 'IFF file'
11:48:43 AM: Debug: Adding duplicate image handler for 'Windows icon file'
11:48:43 AM: Debug: Adding duplicate image handler for 'Windows cursor file'
11:48:43 AM: Debug: Adding duplicate image handler for 'Windows animated cursor file'
11:48:43 AM: Debug: Adding duplicate image handler for 'TGA file'
11:48:43 AM: Debug: Adding duplicate image handler for 'XPM file'
11:48:43 AM: Debug: Adding duplicate image handler for 'PNG file'
11:48:43 AM: Debug: Adding duplicate image handler for 'JPEG file'
11:48:43 AM: Debug: Adding duplicate image handler for 'TIFF file'
11:48:43 AM: Debug: Adding duplicate image handler for 'GIF file'
11:48:43 AM: Debug: Adding duplicate image handler for 'PNM file'
11:48:43 AM: Debug: Adding duplicate image handler for 'PCX file'
11:48:43 AM: Debug: Adding duplicate image handler for 'IFF file'
11:48:43 AM: Debug: Adding duplicate image handler for 'Windows icon file'
11:48:43 AM: Debug: Adding duplicate image handler for 'Windows cursor file'
11:48:43 AM: Debug: Adding duplicate image handler for 'Windows animated cursor file'
11:48:43 AM: Debug: Adding duplicate image handler for 'TGA file'
11:48:43 AM: Debug: Adding duplicate image handler for 'XPM file'
11:48:43 AM: Debug: Adding duplicate image handler for 'PNG file'
11:48:43 AM: Debug: Adding duplicate image handler for 'JPEG file'
11:48:43 AM: Debug: Adding duplicate image handler for 'TIFF file'
11:48:43 AM: Debug: Adding duplicate image handler for 'GIF file'
11:48:43 AM: Debug: Adding duplicate image handler for 'PNM file'
11:48:43 AM: Debug: Adding duplicate image handler for 'PCX file'
11:48:43 AM: Debug: Adding duplicate image handler for 'IFF file'
11:48:43 AM: Debug: Adding duplicate image handler for 'Windows icon file'
11:48:43 AM: Debug: Adding duplicate image handler for 'Windows cursor file'
11:48:43 AM: Debug: Adding duplicate image handler for 'Windows animated cursor file'
11:48:43 AM: Debug: Adding duplicate image handler for 'TGA file'
11:48:43 AM: Debug: Adding duplicate image handler for 'XPM file'
11:48:43 AM: Debug: Adding duplicate image handler for 'PNG file'
11:48:43 AM: Debug: Adding duplicate image handler for 'JPEG file'
11:48:43 AM: Debug: Adding duplicate image handler for 'TIFF file'
11:48:43 AM: Debug: Adding duplicate image handler for 'GIF file'
11:48:43 AM: Debug: Adding duplicate image handler for 'PNM file'
11:48:43 AM: Debug: Adding duplicate image handler for 'PCX file'
11:48:43 AM: Debug: Adding duplicate image handler for 'IFF file'
11:48:43 AM: Debug: Adding duplicate image handler for 'Windows icon file'
11:48:43 AM: Debug: Adding duplicate image handler for 'Windows cursor file'
11:48:43 AM: Debug: Adding duplicate image handler for 'Windows animated cursor file'
11:48:43 AM: Debug: Adding duplicate image handler for 'TGA file'
11:48:43 AM: Debug: Adding duplicate image handler for 'XPM file'
libc++abi: terminating due to uncaught exception of type std::out_of_range: aGlobalIndex-th vertex does not exist
Fatal Python error: Aborted

Current thread 0x0000000200eea080 (most recent call first):
  File "/Applications/KiCad/KiCad.app/Contents/Frameworks/Python.framework/Versions/3.9/lib/python3.9/site-packages/pcbnew.py", line 10191 in Move
  File "/Users/mairas/src/yaqwsx/KiKit/kikit/panelize.py", line 2383 in translate
  File "/Users/mairas/src/yaqwsx/KiKit/kikit/panelize_ui_impl.py", line 690 in positionPanel
  File "/Users/mairas/src/yaqwsx/KiKit/kikit/panelize_ui.py", line 300 in doPanelization
  File "/Users/mairas/src/yaqwsx/KiKit/kikit/panelize_ui.py", line 217 in panelize
  File "/Applications/KiCad/KiCad.app/Contents/Frameworks/Python.framework/Versions/3.9/lib/python3.9/site-packages/click/core.py", line 788 in invoke
  File "/Applications/KiCad/KiCad.app/Contents/Frameworks/Python.framework/Versions/3.9/lib/python3.9/site-packages/click/core.py", line 1443 in invoke
  File "/Applications/KiCad/KiCad.app/Contents/Frameworks/Python.framework/Versions/3.9/lib/python3.9/site-packages/click/core.py", line 1697 in invoke
  File "/Applications/KiCad/KiCad.app/Contents/Frameworks/Python.framework/Versions/3.9/lib/python3.9/site-packages/click/core.py", line 1082 in main
  File "/Applications/KiCad/KiCad.app/Contents/Frameworks/Python.framework/Versions/3.9/lib/python3.9/site-packages/click/core.py", line 1161 in __call__
  File "/Users/mairas/src/yaqwsx/KiKit/kikit/ui.py", line 28 in <module>
  File "/Applications/KiCad/KiCad.app/Contents/Frameworks/Python.framework/Versions/3.9/lib/python3.9/runpy.py", line 87 in _run_code
  File "/Applications/KiCad/KiCad.app/Contents/Frameworks/Python.framework/Versions/3.9/lib/python3.9/runpy.py", line 197 in _run_module_as_main
/usr/local/bin/kikit: line 2: 97009 Abort trap: 6           /Applications/KiCad/KiCad.app/Contents/Frameworks/Python.framework/Versions/3.9/bin/python3 -m kikit.ui "$@"

Steps to Reproduce

Run the command provided above.

I have pinned this issue down to commit b4f2692 (Prevent interference of neighboring boards polygons). Before that commit, no crash. After that commit, crash.

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