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Exporting STEP failed with BRepAdaptor_Curve::No geometry in KiCad 7

Description

I have a board outline I imported from a DXF file which causes the KiCad STEP export to fail.

The export fails with this error:

Loading board
Determining PCB data
Board Thickness from stackup: 1.600 mm
Build STEP data
Create PCB solid model
Board outline: find 384 initial points
Build board main outline 1 with 384 points.
OCC exception: BRepAdaptor_Curve::No geometry
OCC error adding main outline polygon 1 with 384 points.

Generate board full shape.
Writing STEP file
No valid PCB assembly; cannot create output file '/path/to/outline-test.step'.

** Error writing STEP file. **

This happens no matter the settings for the STEP export.

This issue affects KiCad 7.0.5, but seems to be fine with the latest nightly build.

Steps to reproduce

  • Download this minimal example file: outline-test.kicad_pcb
  • File -> Export -> STEP..
  • Expect the export to succeed

This file succeeds with KiCad nightly but fails with 7.0.5.

KiCad Version

Application: KiCad PCB Editor arm64 on arm64

Version: 7.0.5-0, release build

Libraries:
	wxWidgets 3.2.2
	FreeType 2.12.1
	HarfBuzz 5.3.1
	FontConfig 2.14.0
	libcurl/7.88.1 (SecureTransport) LibreSSL/3.3.6 zlib/1.2.11 nghttp2/1.51.0

Platform: macOS Ventura Version 13.4 (Build 22F66), 64 bit, Little endian, wxMac

Build Info:
	Date: May 26 2023 08:14:40
	wxWidgets: 3.2.2 (wchar_t,wx containers)
	Boost: 1.80.0
	OCC: 7.6.3
	Curl: 7.77.0
	ngspice: 38
	Compiler: Clang 13.0.0 with C++ ABI 1002

Build settings:
	KICAD_SPICE=ON

Nightly build I tested with

Application: KiCad PCB Editor arm64 on arm64

Version: 7.99.0-1350-g1ed4cd3644, release build

Libraries:
	wxWidgets 3.2.2
	FreeType 2.12.1
	HarfBuzz 5.3.1
	FontConfig 2.14.0
	libcurl/7.88.1 (SecureTransport) LibreSSL/3.3.6 zlib/1.2.11 nghttp2/1.51.0

Platform: macOS Ventura Version 13.4 (Build 22F66), 64 bit, Little endian, wxMac

Build Info:
	Date: Jun  6 2023 01:20:23
	wxWidgets: 3.2.2 (wchar_t,wx containers)
	Boost: 1.80.0
	OCC: 7.6.3
	Curl: 7.77.0
	ngspice: 40
	Compiler: Clang 13.0.0 with C++ ABI 1002

Build settings: