ADDED: XAO export for SALOME / Gmsh workflows.

Pad surfaces are assigned as face groups.

common/jobs/job_export_pcb_3d.h

@@ -35,6 +35,7 @@ public:
         UNKNOWN, // defefer to arg
         STEP,
         BREP,
+        XAO,
         GLB,
         VRML
     };

common/wildcards_and_files_ext.cpp

@@ -3,7 +3,7 @@
  *
  * Copyright (C) 2018 Jean-Pierre Charras, jp.charras at wanadoo.fr
  * Copyright (C) 2008 Wayne Stambaugh <stambaughw@gmail.com>
- * Copyright (C) 1992-2023 KiCad Developers, see AUTHORS.txt for contributors.
+ * Copyright (C) 1992-2024 KiCad Developers, see AUTHORS.txt for contributors.
  *
  * This program is free software; you can redistribute it and/or
  * modify it under the terms of the GNU General Public License
@@ -198,6 +198,7 @@ const std::string FILEEXT::StepFileExtension( "step" );
 const std::string FILEEXT::StepFileAbrvExtension( "stp" );
 const std::string FILEEXT::GltfBinaryFileExtension( "glb" );
 const std::string FILEEXT::BrepFileExtension( "brep" );
+const std::string FILEEXT::XaoFileExtension( "xao" );
 
 const wxString FILEEXT::GerberFileExtensionsRegex( "(gbr|gko|pho|(g[tb][alops])|(gm?\\d\\d*)|(gp[tb]))" );
 

include/wildcards_and_files_ext.h

@@ -4,7 +4,7 @@
  * Copyright (C) 2018 Jean-Pierre Charras, jp.charras at wanadoo.fr
  * Copyright (C) 2007-2012 SoftPLC Corporation, Dick Hollenbeck <dick@softplc.com>
  * Copyright (C) 2008 Wayne Stambaugh <stambaughw@gmail.com>
- * Copyright (C) 1992-2023 KiCad Developers, see AUTHORS.txt for contributors.
+ * Copyright (C) 1992-2024 KiCad Developers, see AUTHORS.txt for contributors.
  *
  * This program is free software; you can redistribute it and/or
  * modify it under the terms of the GNU General Public License
@@ -188,6 +188,7 @@ public:
     static const std::string StepFileAbrvExtension;
     static const std::string GltfBinaryFileExtension;
     static const std::string BrepFileExtension;
+    static const std::string XaoFileExtension;
 
     static const wxString GerberFileExtensionsRegex;
 

kicad/cli/command_pcb_export_3d.cpp

@@ -69,7 +69,7 @@ CLI::PCB_EXPORT_3D_COMMAND::PCB_EXPORT_3D_COMMAND( const std::string&        aNa
         m_argParser.add_argument( ARG_FORMAT )
                 .default_value( std::string( "step" ) )
                 .help( UTF8STDSTR(
-                        _( "Output file format, options: step, brep, glb (binary glTF)" ) ) );
+                        _( "Output file format, options: step, brep, xao, glb (binary glTF)" ) ) );
     }
 
     m_argParser.add_argument( ARG_FORCE, "-f" )
@@ -88,6 +88,7 @@ CLI::PCB_EXPORT_3D_COMMAND::PCB_EXPORT_3D_COMMAND( const std::string&        aNa
             .flag();
 
     if( m_format == JOB_EXPORT_PCB_3D::FORMAT::STEP || m_format == JOB_EXPORT_PCB_3D::FORMAT::BREP
+        || m_format == JOB_EXPORT_PCB_3D::FORMAT::XAO
         || m_format == JOB_EXPORT_PCB_3D::FORMAT::GLB )
     {
         m_argParser.add_argument( ARG_GRID_ORIGIN )
@@ -181,6 +182,7 @@ int CLI::PCB_EXPORT_3D_COMMAND::doPerform( KIWAY& aKiway )
     std::unique_ptr<JOB_EXPORT_PCB_3D> step( new JOB_EXPORT_PCB_3D( true ) );
 
     if( m_format == JOB_EXPORT_PCB_3D::FORMAT::STEP || m_format == JOB_EXPORT_PCB_3D::FORMAT::BREP
+        || m_format == JOB_EXPORT_PCB_3D::FORMAT::XAO
         || m_format == JOB_EXPORT_PCB_3D::FORMAT::GLB )
     {
         step->m_useDrillOrigin = m_argParser.get<bool>( ARG_DRILL_ORIGIN );
@@ -217,6 +219,8 @@ int CLI::PCB_EXPORT_3D_COMMAND::doPerform( KIWAY& aKiway )
             step->m_format = JOB_EXPORT_PCB_3D::FORMAT::STEP;
         else if( format == wxS( "brep" ) )
             step->m_format = JOB_EXPORT_PCB_3D::FORMAT::BREP;
+        else if( format == wxS( "xao" ) )
+            step->m_format = JOB_EXPORT_PCB_3D::FORMAT::XAO;
         else if( format == wxS( "glb" ) )
             step->m_format = JOB_EXPORT_PCB_3D::FORMAT::GLB;
         else
@@ -296,6 +300,7 @@ int CLI::PCB_EXPORT_3D_COMMAND::doPerform( KIWAY& aKiway )
     }
 
     if( m_format == JOB_EXPORT_PCB_3D::FORMAT::STEP || m_format == JOB_EXPORT_PCB_3D::FORMAT::BREP
+        || m_format == JOB_EXPORT_PCB_3D::FORMAT::XAO
         || m_format == JOB_EXPORT_PCB_3D::FORMAT::GLB )
     {
         wxString minDistance =

kicad/kicad_cli.cpp

@@ -113,6 +113,7 @@ static CLI::PCB_EXPORT_DXF_COMMAND       exportPcbDxfCmd{};
 static CLI::PCB_EXPORT_3D_COMMAND        exportPcbGlbCmd{ "glb", UTF8STDSTR( _( "Export GLB (binary GLTF)" ) ), JOB_EXPORT_PCB_3D::FORMAT::GLB };
 static CLI::PCB_EXPORT_3D_COMMAND        exportPcbStepCmd{ "step", UTF8STDSTR( _( "Export STEP" ) ), JOB_EXPORT_PCB_3D::FORMAT::STEP };
 static CLI::PCB_EXPORT_3D_COMMAND        exportPcbBrepCmd{ "brep", UTF8STDSTR( _( "Export BREP" ) ), JOB_EXPORT_PCB_3D::FORMAT::BREP };
+static CLI::PCB_EXPORT_3D_COMMAND        exportPcbXaoCmd{ "xao", UTF8STDSTR( _( "Export XAO" ) ), JOB_EXPORT_PCB_3D::FORMAT::XAO };
 static CLI::PCB_EXPORT_3D_COMMAND        exportPcbVrmlCmd{ "vrml", UTF8STDSTR( _( "Export VRML" ) ), JOB_EXPORT_PCB_3D::FORMAT::VRML };
 static CLI::PCB_EXPORT_SVG_COMMAND       exportPcbSvgCmd{};
 static CLI::PCB_EXPORT_PDF_COMMAND       exportPcbPdfCmd{};
@@ -181,7 +182,8 @@ static std::vector<COMMAND_ENTRY> commandStack = {
                     &exportPcbPosCmd,
                     &exportPcbStepCmd,
                     &exportPcbSvgCmd,
-                    &exportPcbVrmlCmd
+                    &exportPcbVrmlCmd,
+                    &exportPcbXaoCmd
                 }
             }
         }

pcbnew/dialogs/dialog_export_step.cpp

@@ -480,6 +480,8 @@ void DIALOG_EXPORT_STEP::onExportButton( wxCommandEvent& aEvent )
         cmdK2S.Append( wxT( " glb" ) );
     else if( fn.GetExt() == FILEEXT::BrepFileExtension )
         cmdK2S.Append( wxT( " brep" ) );
+    else if( fn.GetExt() == FILEEXT::XaoFileExtension )
+        cmdK2S.Append( wxT( " xao" ) );
     else
         cmdK2S.Append( wxT( " step" ) );
 

pcbnew/dialogs/dialog_export_step_base.fbp

@@ -51,7 +51,7 @@
       <property name="size">-1,-1</property>
       <property name="style">wxDEFAULT_DIALOG_STYLE|wxRESIZE_BORDER</property>
       <property name="subclass">DIALOG_SHIM; dialog_shim.h</property>
-      <property name="title">Export STEP / BREP / GLTF</property>
+      <property name="title">Export STEP / BREP / XAO / GLTF</property>
       <property name="tooltip"></property>
       <property name="two_step_creation">0</property>
       <property name="window_extra_style"></property>

pcbnew/dialogs/dialog_export_step_base.h

@@ -95,7 +95,7 @@ class DIALOG_EXPORT_STEP_BASE : public DIALOG_SHIM
 
 	public:
 
-		DIALOG_EXPORT_STEP_BASE( wxWindow* parent, wxWindowID id = wxID_ANY, const wxString& title = _("Export STEP / BREP / GLTF"), const wxPoint& pos = wxDefaultPosition, const wxSize& size = wxSize( -1,-1 ), long style = wxDEFAULT_DIALOG_STYLE|wxRESIZE_BORDER );
+		DIALOG_EXPORT_STEP_BASE( wxWindow* parent, wxWindowID id = wxID_ANY, const wxString& title = _("Export STEP / BREP / XAO / GLTF"), const wxPoint& pos = wxDefaultPosition, const wxSize& size = wxSize( -1,-1 ), long style = wxDEFAULT_DIALOG_STYLE|wxRESIZE_BORDER );
 
 		~DIALOG_EXPORT_STEP_BASE();
 

pcbnew/exporters/step/exporter_step.cpp

@@ -121,6 +121,7 @@ wxString EXPORTER_STEP_PARAMS::GetDefaultExportExtension()
     {
     case EXPORTER_STEP_PARAMS::FORMAT::STEP: return wxS( "step" );
     case EXPORTER_STEP_PARAMS::FORMAT::BREP: return wxS( "brep" );
+    case EXPORTER_STEP_PARAMS::FORMAT::XAO:  return wxS( "xao" );
     case EXPORTER_STEP_PARAMS::FORMAT::GLB:  return wxS( "glb" );
     default:                                 return wxEmptyString; // shouldn't happen
     }
@@ -133,6 +134,7 @@ wxString EXPORTER_STEP_PARAMS::GetFormatName()
     // honestly these names shouldn't be translated since they are mostly industry standard acronyms
     case EXPORTER_STEP_PARAMS::FORMAT::STEP: return wxS( "STEP" );
     case EXPORTER_STEP_PARAMS::FORMAT::BREP: return wxS( "BREP" );
+    case EXPORTER_STEP_PARAMS::FORMAT::XAO:  return wxS( "XAO" );
     case EXPORTER_STEP_PARAMS::FORMAT::GLB:  return wxS( "Binary GLTF" );
     default:                                 return wxEmptyString; // shouldn't happen
     }
@@ -542,6 +544,8 @@ bool EXPORTER_STEP::Export()
             success = m_pcbModel->WriteSTEP( m_outputFile, m_params.m_optimizeStep );
         else if( m_params.m_format == EXPORTER_STEP_PARAMS::FORMAT::BREP )
             success = m_pcbModel->WriteBREP( m_outputFile );
+        else if( m_params.m_format == EXPORTER_STEP_PARAMS::FORMAT::XAO )
+            success = m_pcbModel->WriteXAO( m_outputFile );
         else if( m_params.m_format == EXPORTER_STEP_PARAMS::FORMAT::GLB )
             success = m_pcbModel->WriteGLTF( m_outputFile );
 

pcbnew/exporters/step/exporter_step.h

@@ -3,7 +3,7 @@
  *
  * Copyright (C) 2022 Mark Roszko <mark.roszko@gmail.com>
  * Copyright (C) 2016 Cirilo Bernardo <cirilo.bernardo@gmail.com>
- * Copyright (C) 2016-2023 KiCad Developers, see AUTHORS.txt for contributors.
+ * Copyright (C) 2016-2024 KiCad Developers, see AUTHORS.txt for contributors.
  *
  * This program is free software; you can redistribute it and/or
  * modify it under the terms of the GNU General Public License
@@ -69,6 +69,7 @@ public:
     {
         STEP,
         BREP,
+        XAO,
         GLB
     };
 

pcbnew/exporters/step/step_pcb_model.cpp

@@ -62,6 +62,7 @@
 #include <STEPCAFControl_Writer.hxx>
 #include <APIHeaderSection_MakeHeader.hxx>
 #include <Standard_Failure.hxx>
+#include <Standard_Handle.hxx>
 #include <Standard_Version.hxx>
 #include <TCollection_ExtendedString.hxx>
 #include <TDocStd_Document.hxx>
@@ -70,6 +71,7 @@
 #include <TDF_LabelSequence.hxx>
 #include <TDF_ChildIterator.hxx>
 #include <TopExp_Explorer.hxx>
+#include <TopoDS.hxx>
 #include <XCAFApp_Application.hxx>
 #include <XCAFDoc.hxx>
 #include <XCAFDoc_DocumentTool.hxx>
@@ -84,10 +86,13 @@
 #include <BRepBuilderAPI_MakeEdge.hxx>
 #include <BRepBuilderAPI_MakeWire.hxx>
 #include <BRepBuilderAPI_MakeFace.hxx>
+#include <BRepBuilderAPI_MakeVertex.hxx>
+#include <BRepExtrema_DistShapeShape.hxx>
 #include <BRepPrimAPI_MakePrism.hxx>
 #include <BRepPrimAPI_MakeCylinder.hxx>
 #include <BRepTools.hxx>
 #include <BRepLib_MakeWire.hxx>
+#include <BRepAdaptor_Surface.hxx>
 #include <BRepAlgoAPI_Check.hxx>
 #include <BRepAlgoAPI_Cut.hxx>
 #include <BRepAlgoAPI_Fuse.hxx>
@@ -438,6 +443,8 @@ bool STEP_PCB_MODEL::AddPadShape( const PAD* aPad, const VECTOR2D& aOrigin, bool
                 thickness -= 0.01;
         }
 
+        TopoDS_Shape testShape;
+
         // Make a shape on copper layers
         std::shared_ptr<SHAPE> effShapePtr = aPad->GetEffectiveShape( pcb_layer );
 
@@ -475,6 +482,12 @@ bool STEP_PCB_MODEL::AddPadShape( const PAD* aPad, const VECTOR2D& aOrigin, bool
                                              aOrigin ) )
                 {
                     topodsShapes.emplace_back( topods_shape );
+
+                    if( testShape.IsNull() )
+                    {
+                        MakeShapeAsThickSegment( testShape, start, end, width, 0.0,
+                                                 Zpos + thickness, aOrigin );
+                    }
                 }
                 else
                 {
@@ -487,6 +500,16 @@ bool STEP_PCB_MODEL::AddPadShape( const PAD* aPad, const VECTOR2D& aOrigin, bool
                 shape->TransformToPolygon( polySet, ARC_HIGH_DEF, ERROR_INSIDE );
 
                 success &= MakeShapes( topodsShapes, polySet, false, thickness, Zpos, aOrigin );
+
+                if( testShape.IsNull() )
+                {
+                    std::vector<TopoDS_Shape> testShapes;
+
+                    MakeShapes( testShapes, polySet, false, 0.0, Zpos + thickness, aOrigin );
+
+                    if( testShapes.size() > 0 )
+                        testShape = testShapes.front();
+                }
             }
         }
 
@@ -544,6 +567,29 @@ bool STEP_PCB_MODEL::AddPadShape( const PAD* aPad, const VECTOR2D& aOrigin, bool
                     m_board_copper_pads.emplace_back( sh );
             }
         }
+
+        if( !aVia && !testShape.IsNull() )
+        {
+            if( pcb_layer == F_Cu || pcb_layer == B_Cu )
+            {
+                wxString name;
+
+                name << "Pad_";
+
+                if( pcb_layer == F_Cu )
+                    name << 'F' << '_';
+                else if( pcb_layer == B_Cu )
+                    name << 'B' << '_';
+
+                name << aPad->GetParentFootprint()->GetReferenceAsString() << '_'
+                     << aPad->GetNumber() << '_' << aPad->GetShortNetname();
+
+                gp_Pnt point( pcbIUScale.IUTomm( aPad->GetX() - aOrigin.x ),
+                              -pcbIUScale.IUTomm( aPad->GetY() - aOrigin.y ), Zpos + thickness );
+
+                m_pad_points[name] = { point, testShape };
+            }
+        }
     }
 
     if( aPad->GetAttribute() == PAD_ATTRIB::PTH && aPad->IsOnLayer( F_Cu )
@@ -1034,12 +1080,13 @@ bool STEP_PCB_MODEL::MakeShapeAsThickSegment( TopoDS_Shape& aShape,
     }
     catch( const Standard_Failure& e )
     {
-        ReportMessage(
+        ReportMessage( wxString::Format( wxT( "MakeShapeThickSegment: OCC exception: %s\n" ),
-                wxString::Format( wxT( "MakeShapeThickSegment: OCC exception: %s\n" ),
                                          e.GetMessageString() ) );
         return false;
     }
 
+    if( aThickness != 0.0 )
+    {
         aShape = BRepPrimAPI_MakePrism( face, gp_Vec( 0, 0, aThickness ) );
 
         if( aShape.IsNull() )
@@ -1047,6 +1094,11 @@ bool STEP_PCB_MODEL::MakeShapeAsThickSegment( TopoDS_Shape& aShape,
             ReportMessage( wxT( "failed to create a prismatic shape\n" ) );
             return false;
         }
+    }
+    else
+    {
+        aShape = face;
+    }
 
     return success;
 }
@@ -1139,8 +1191,7 @@ bool STEP_PCB_MODEL::MakeShapes( std::vector<TopoDS_Shape>& aShapes, const SHAPE
                     }
                     else
                     {
-                        curve = GC_MakeArcOfCircle( toPoint( aPt0 ),
+                        curve = GC_MakeArcOfCircle( toPoint( aPt0 ), toPoint( aArc.GetArcMid() ),
-                                                    toPoint( aArc.GetArcMid() ),
                                                     toPoint( aArc.GetP1() ) )
                                         .Value();
                     }
@@ -1341,6 +1392,8 @@ bool STEP_PCB_MODEL::MakeShapes( std::vector<TopoDS_Shape>& aShapes, const SHAPE
         }
 
         if( mkFace.IsDone() )
+        {
+            if( aThickness != 0.0 )
             {
                 TopoDS_Shape prism = BRepPrimAPI_MakePrism( mkFace, gp_Vec( 0, 0, aThickness ) );
                 aShapes.push_back( prism );
@@ -1352,6 +1405,11 @@ bool STEP_PCB_MODEL::MakeShapes( std::vector<TopoDS_Shape>& aShapes, const SHAPE
                 }
             }
             else
+            {
+                aShapes.push_back( mkFace );
+            }
+        }
+        else
         {
             wxASSERT( false );
         }
@@ -1849,6 +1907,163 @@ bool STEP_PCB_MODEL::WriteBREP( const wxString& aFileName )
 }
 
 
+bool STEP_PCB_MODEL::WriteXAO( const wxString& aFileName )
+{
+    wxFileName fn( aFileName );
+
+    wxFFileOutputStream ffStream( fn.GetFullPath() );
+    wxStdOutputStream   file( ffStream );
+
+    if( !ffStream.IsOk() )
+    {
+        ReportMessage( wxString::Format( "Could not open file '%s'", fn.GetFullPath() ) );
+        return false;
+    }
+
+    // s_assy = shape tool for the source
+    Handle( XCAFDoc_ShapeTool ) s_assy = XCAFDoc_DocumentTool::ShapeTool( m_doc->Main() );
+
+    // retrieve the shape from the assembly
+    const TopoDS_Shape shape = s_assy->GetOneShape();
+
+    std::map<wxString, std::vector<int>> groups[4];
+    TopExp_Explorer                      exp;
+    int                                  faceIndex = 0;
+
+    for( exp.Init( shape, TopAbs_FACE ); exp.More(); exp.Next() )
+    {
+        TopoDS_Shape subShape = exp.Current();
+
+        Bnd_Box bbox;
+        BRepBndLib::Add( subShape, bbox );
+
+        for( const auto& [padKey, pair] : m_pad_points )
+        {
+            const auto& [point, padTestShape] = pair;
+
+            if( bbox.IsOut( point ) )
+                continue;
+
+            BRepAdaptor_Surface surface( TopoDS::Face( subShape ) );
+
+            if( surface.GetType() != GeomAbs_Plane )
+                continue;
+
+            BRepExtrema_DistShapeShape dist( padTestShape, subShape );
+            dist.Perform();
+
+            if( !dist.IsDone() )
+                continue;
+
+            std::cout << padKey << " " << dist.Value() << std::endl;
+
+            if( dist.Value() < Precision::Approximation() )
+            {
+                // Push as a face group
+                groups[2][padKey].push_back( faceIndex );
+            }
+        }
+
+        faceIndex++;
+    }
+
+    // Based on Gmsh code
+    file << "<?xml version=\"1.0\" encoding=\"UTF-8\"?>" << std::endl;
+    file << "<XAO version=\"1.0\" author=\"KiCad\">" << std::endl;
+    file << "  <geometry name=\"" << fn.GetName() << "\">" << std::endl;
+    file << "    <shape format=\"BREP\"><![CDATA[";
+#if OCC_VERSION_HEX < 0x070600
+    BRepTools::Write( shape, file );
+#else
+    BRepTools::Write( shape, file, Standard_True, Standard_True, TopTools_FormatVersion_VERSION_1 );
+#endif
+    file << "]]></shape>" << std::endl;
+    file << "    <topology>" << std::endl;
+
+    TopTools_IndexedMapOfShape mainMap;
+    TopExp::MapShapes( shape, mainMap );
+    std::set<int> topo[4];
+
+    static const TopAbs_ShapeEnum c_dimShapeTypes[] = { TopAbs_VERTEX, TopAbs_EDGE, TopAbs_FACE,
+                                                        TopAbs_SOLID };
+
+    static const std::string c_dimLabel[] = { "vertex", "edge", "face", "solid" };
+    static const std::string c_dimLabels[] = { "vertices", "edges", "faces", "solids" };
+
+    for( int dim = 0; dim < 4; dim++ )
+    {
+        for( exp.Init( shape, c_dimShapeTypes[dim] ); exp.More(); exp.Next() )
+        {
+            TopoDS_Shape subShape = exp.Current();
+            int          idx = mainMap.FindIndex( subShape );
+
+            if( idx && !topo[dim].count( idx ) )
+                topo[dim].insert( idx );
+        }
+    }
+
+    for( int dim = 0; dim <= 3; dim++ )
+    {
+        std::string labels = c_dimLabels[dim];
+        std::string label = c_dimLabel[dim];
+
+        file << "      <" << labels << " count=\"" << topo[dim].size() << "\">" << std::endl;
+        int index = 0;
+
+        for( auto p : topo[dim] )
+        {
+            std::string name( "" );
+            file << "        <" << label << " index=\"" << index << "\" "
+                 << "name=\"" << name << "\" "
+                 << "reference=\"" << p << "\"/>" << std::endl;
+
+            index++;
+        }
+        file << "      </" << labels << ">" << std::endl;
+    }
+
+    file << "    </topology>" << std::endl;
+    file << "  </geometry>" << std::endl;
+    file << "  <groups count=\""
+         << groups[0].size() + groups[1].size() + groups[2].size() + groups[3].size() << "\">"
+         << std::endl;
+    for( int dim = 0; dim <= 3; dim++ )
+    {
+        std::string label = c_dimLabel[dim];
+
+        for( auto g : groups[dim] )
+        {
+            //std::string name = model->getPhysicalName( dim, g.first );
+            wxString name = g.first;
+
+            if( name.empty() )
+            { // create same unique name as for MED export
+                std::ostringstream gs;
+                gs << "G_" << dim << "D_" << g.first;
+                name = gs.str();
+            }
+            file << "    <group name=\"" << name << "\" dimension=\"" << label;
+//#if 1
+//            // Gmsh XAO extension: also save the physical tag, so that XAO can be used
+//            // to serialize OCC geometries, ready to be used by GetDP, GmshFEM & co
+//            file << "\" tag=\"" << g.first;
+//#endif
+            file << "\" count=\"" << g.second.size() << "\">" << std::endl;
+            for( auto index : g.second )
+            {
+                file << "      <element index=\"" << index << "\"/>" << std::endl;
+            }
+            file << "    </group>" << std::endl;
+        }
+    }
+    file << "  </groups>" << std::endl;
+    file << "  <fields count=\"0\"/>" << std::endl;
+    file << "</XAO>" << std::endl;
+
+    return true;
+}
+
+
 bool STEP_PCB_MODEL::getModelLabel( const std::string& aFileNameUTF8, VECTOR3D aScale, TDF_Label& aLabel,
                               bool aSubstituteModels, wxString* aErrorMessage )
 {

pcbnew/exporters/step/step_pcb_model.h

@@ -176,6 +176,9 @@ public:
     // write the assembly in BREP format
     bool WriteBREP( const wxString& aFileName );
 
+    // write the assembly in XAO format with pad faces as groups
+    bool WriteXAO( const wxString& aFileName );
+
     /**
      * Write the assembly in binary GLTF Format
      *
@@ -259,6 +262,9 @@ private:
     std::vector<TopoDS_Shape> m_board_copper_pads;
     std::vector<TopoDS_Shape> m_board_copper_fused;
 
+    // Data for pads
+    std::map<wxString, std::pair<gp_Pnt, TopoDS_Shape>> m_pad_points;
+
     /// Name of the PCB, which will most likely be the file name of the path.
     wxString                        m_pcbName;
 

pcbnew/menubar_pcb_editor.cpp

@@ -4,7 +4,7 @@
  * Copyright (C) 2017 Jean-Pierre Charras, jp.charras at wanadoo.fr
  * Copyright (C) 2012 SoftPLC Corporation, Dick Hollenbeck <dick@softplc.com>
  * Copyright (C) 2012 Wayne Stambaugh <stambaughw@gmail.com>
- * Copyright (C) 1992-2022 KiCad Developers, see AUTHORS.txt for contributors.
+ * Copyright (C) 1992-2024 KiCad Developers, see AUTHORS.txt for contributors.
  *
  * This program is free software; you can redistribute it and/or
  * modify it under the terms of the GNU General Public License
@@ -133,7 +133,7 @@ void PCB_EDIT_FRAME::doReCreateMenuBar()
                         ID_GEN_EXPORT_FILE_VRML, BITMAPS::export3d );
     submenuExport->Add( _( "IDFv3..." ), _( "Export IDF 3D board representation" ),
                         ID_GEN_EXPORT_FILE_IDF3, BITMAPS::export_idf );
-    submenuExport->Add( _( "STEP..." ), _( "Export STEP 3D board representation" ),
+    submenuExport->Add( _( "STEP / BREP / XAO..." ), _( "Export STEP / BREP / XAO 3D board representation" ),
                         ID_GEN_EXPORT_FILE_STEP, BITMAPS::export_step );
     submenuExport->Add( _( "SVG..." ), _( "Export SVG board representation" ),
                         ID_GEN_PLOT_SVG, BITMAPS::export_svg );

pcbnew/pcbnew_jobs_handler.cpp

@@ -135,6 +135,8 @@ int PCBNEW_JOBS_HANDLER::JobExportStep( JOB* aJob )
             break;
         case JOB_EXPORT_PCB_3D::FORMAT::BREP: fn.SetExt( FILEEXT::BrepFileExtension );
             break;
+        case JOB_EXPORT_PCB_3D::FORMAT::XAO: fn.SetExt( FILEEXT::XaoFileExtension );
+            break;
         case JOB_EXPORT_PCB_3D::FORMAT::GLB: fn.SetExt( FILEEXT::GltfBinaryFileExtension );
             break;
         default:
@@ -216,6 +218,9 @@ int PCBNEW_JOBS_HANDLER::JobExportStep( JOB* aJob )
         case JOB_EXPORT_PCB_3D::FORMAT::BREP:
             params.m_format = EXPORTER_STEP_PARAMS::FORMAT::BREP;
             break;
+        case JOB_EXPORT_PCB_3D::FORMAT::XAO:
+            params.m_format = EXPORTER_STEP_PARAMS::FORMAT::XAO;
+            break;
         case JOB_EXPORT_PCB_3D::FORMAT::GLB:
             params.m_format = EXPORTER_STEP_PARAMS::FORMAT::GLB;
             break;