ci(hardware): headless KiCad ERC/DRC and schematic exports

.github/workflows/hardware-check.yml

@@ -0,0 +1,44 @@
+name: hardware-check
+
+on:
+  push:
+    branches: [main]
+    paths:
+      - "hardware/**"
+      - ".github/workflows/hardware-check.yml"
+  pull_request:
+    paths:
+      - "hardware/**"
+      - ".github/workflows/hardware-check.yml"
+  workflow_dispatch:
+
+# Headless KiCad: ERC on the rev2 schematic, DRC on every board that has an
+# outline, and SVG/PDF exports of the rev2 sheets as a downloadable artifact.
+# Mirrors hardware/rev2/tools/kicad-check.sh — keep the two in step.
+# Image pinned by digest (constitution III): kicad/kicad:10.0 @ 2026-09-02.
+env:
+  KICAD_IMAGE: kicad/kicad:10.0@sha256:fdcfa0e8d41f640d16edfb28e027fe8862ab31af9e45dcacbc662cec5c916e4c
+
+jobs:
+  kicad:
+    runs-on: ubuntu-latest
+    steps:
+      - name: Checkout
+        uses: actions/checkout@v4
+
+      - name: ERC + DRC + exports (kicad-cli in container)
+        run: |
+          docker run --rm --user root -v "$PWD":/work -w /work \
+            -e KICAD_CLI=kicad-cli -e HOME=/tmp "$KICAD_IMAGE" \
+            bash hardware/rev2/tools/kicad-check.sh
+
+      - name: Upload reports and schematic exports
+        if: always()
+        uses: actions/upload-artifact@v4
+        with:
+          name: kicad-rev2-exports
+          path: |
+            hardware/rev2/export/*.rpt
+            hardware/rev2/export/*.pdf
+            hardware/rev2/export/svg/*.svg
+          if-no-files-found: warn

.gitignore

@@ -84,3 +84,4 @@ docs/user-guide.md
 docs/safety.md
 .playwright-mcp/
 *.lck
+hardware/rev2/export/

CLAUDE.md

@@ -87,6 +87,14 @@ docker run --rm -v "$PWD/firmware":/project -w /project espressif/idf:v6.0.1 idf
 
 Board selection (Kconfig: `BOARD_REV1_DEVKIT` / `BOARD_REV2`), flashing, host tests, and all other build details are documented in `firmware/CLAUDE.md`.
 
+### Hardware checks (KiCad, headless)
+
+```bash
+hardware/rev2/tools/kicad-check.sh   # ERC (rev2 schematic) + DRC (boards with an outline) + SVG/PDF exports → hardware/rev2/export/ (gitignored)
+```
+
+CI runs the same script in the pinned `kicad/kicad:10.0` image on every `hardware/**` change (`.github/workflows/hardware-check.yml`) and uploads the schematic exports as a workflow artifact. Rendered sheets are the way to *look* at the schematic from a session — never redraw a sheet by hand.
+
 ### Arduino legacy (frozen)
 
 Built by CI only, on the `arduino-maintenance` branch (pinned PlatformIO platform + library versions). Do not build it from `main`.

hardware/rev2/tools/kicad-check.sh

@@ -0,0 +1,42 @@
+#!/usr/bin/env bash
+# KiCad headless checks + exports for the rev2 hardware (and rev1 DRC).
+# Same commands CI runs (.github/workflows/hardware-check.yml) — run locally
+# before pushing. Output lands in hardware/rev2/export/ (gitignored).
+#
+#   hardware/rev2/tools/kicad-check.sh            # erc + drc + exports
+#   hardware/rev2/tools/kicad-check.sh erc        # one step only
+#
+# Uses kicad-cli from PATH, else the macOS KiCad 10 bundle.
+set -euo pipefail
+HW="$(cd "$(dirname "$0")/../.." && pwd)"
+REV2="$HW/rev2"; OUT="$REV2/export"; mkdir -p "$OUT"
+KC="${KICAD_CLI:-$(command -v kicad-cli || echo /Applications/KiCad/Kicad10.app/Contents/MacOS/kicad-cli)}"
+step="${1:-all}"; rc=0
+run() { echo "== $*"; "$@" 2>&1 | grep -v '^Fontconfig' || true; }
+
+has_outline() { grep -qE '\(gr_(line|rect|poly|arc|circle)' "$1" && grep -q 'Edge.Cuts' "$1"; }
+
+if [[ $step == all || $step == erc ]]; then
+  echo "### ERC rev2 schematic"
+  "$KC" sch erc -o "$OUT/rev2-erc.rpt" --severity-error --exit-code-violations \
+      "$REV2/WateringSystem-rev2.kicad_sch" 2>&1 | grep -v '^Fontconfig' || rc=1
+fi
+if [[ $step == all || $step == drc ]]; then
+  echo "### DRC rev1 board"
+  "$KC" pcb drc -o "$OUT/rev1-drc.rpt" --severity-error --exit-code-violations \
+      "$HW/WateringSystem.kicad_pcb" 2>&1 | grep -v '^Fontconfig' || rc=1
+  if has_outline "$REV2/WateringSystem-rev2.kicad_pcb"; then
+    echo "### DRC rev2 board"
+    "$KC" pcb drc -o "$OUT/rev2-drc.rpt" --severity-error --exit-code-violations \
+        "$REV2/WateringSystem-rev2.kicad_pcb" 2>&1 | grep -v '^Fontconfig' || rc=1
+  else
+    echo "### DRC rev2 board: SKIPPED — no board outline yet (stage-A modules / stage-B layout pending)"
+  fi
+fi
+if [[ $step == all || $step == export ]]; then
+  echo "### Export rev2 schematic → SVG + PDF"
+  run "$KC" sch export svg -o "$OUT/svg" --no-background-color "$REV2/WateringSystem-rev2.kicad_sch"
+  run "$KC" sch export pdf -o "$OUT/WateringSystem-rev2.pdf" "$REV2/WateringSystem-rev2.kicad_sch"
+fi
+echo "### done (rc=$rc) — reports and exports in $OUT"
+exit $rc