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Manufacturing Export Blocker — D356 / 5V Airwire
Date: 2026-06-19
Project: WiFi Voice AI Hub
Summary
This design should not be considered manufacturing-approved from Flux export evidence yet.
The schematic source nets and Gerber X2 / EDIF evidence reported by the user contain the expected nets, including 3V3, 5V, USB_D_N/P, I2S, mic, speaker, BOOT_IO0, and EN_RESET. However, the IPC-D-356 export reported by the user is inconsistent: it omits many real nets and marks connected pads such as U2-IN, U2-OUT, C1-P1, C7-P1, U1-IO19, U1-IO15, and U1-IO6 as N/C.
Flux DRC also continues to report an airwire on a 5V trace object even though the autorouter reports there are no pins left to route.
Actions Attempted
- Verified schematic source 5V net membership:
- C1:P1
- C2:P1
- C6:P1
- C7:P1
- D1:VBUS
- F1:2
- U2:IN
- U3:VDD_1
- U3:VDD_2
- Deleted only the two flagged 5V trace objects and rerouted; DRC re-flagged replacement trace objects.
- Deleted the entire 5V routed copper and rebuilt it from the schematic net; DRC still re-flagged 5V trace objects.
- Deleted all routed copper for all named nets and rerouted the full board from scratch; DRC reduced to one remaining 5V airwire flag, while autoroute still reports nothing left to route.
Current Evidence
- Schematic netlist: expected named nets are present.
- Autorouter: reports no pins left to route after full-board reroute.
- DRC: still reports 1 airwire error on a 5V trace object.
- Export issue: IPC-D-356 reportedly marks connected pads as N/C despite EDIF/Gerber X2 containing correct net names.
Interpretation
This is most likely a Flux platform/export/checker inconsistency involving physical netlist serialization and/or stale/corrupt DRC state, not a simple missing route that can be fixed by rerouting. The repeated recreation of 5V copper and full-board reroute did not clear the issue.
Manufacturing Position
Do not release this package to fabrication as independently verified until Flux support confirms or fixes:
- IPC-D-356 netlist contains all real nets.
- 5V pads are not exported as N/C.
- DRC airwires are zero, or Flux provides written confirmation that the remaining 5V airwire is a false positive and explains why.
Gerbers may visually contain routed copper, but without a correct IPC-D-356/netlist and clean DRC, this package should not be treated as manufacturing-safe.
Summary
Actions Attempted
Current Evidence
Interpretation
Manufacturing Position
