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01:38
I did run DRC and had no errors. (In the design process, I definitely encountered traces that were too close to the pad, which I fixed.) Pardon my ignorance, but is the soldermask expansion the thin line surrounding a pad in KiCad? You are correct about the via - that's a great point, and I'll fix in in my next revision.
 
2 hours later…
03:44
I'm not super familiar with KiCAD but yeah I'm pretty sure that's what the line is depicting, assuming it's the same as what I would normally see in Altium.
If you put a trace inside the soldermask expansion around a pad there'll be copper exposed very close to the pad. So it's quite possible that you've got a lot of shorts on this board.
 
8 hours later…
11:43
@Reid actually, this might be a cause of the issue as well. The very low impedance ceramic capacitors pull a big inrush current. The long wires from your power supply carry the current and have a large enough inductance to matter. So the inrush current will carry on, after the capacitors are charged. The capacitors will be charged further - so the voltage will rise over the set voltage from your power supply until everything settles down. I'd reduce the wire length as much as possible.
 
3 hours later…
14:59
@Polynomial thanks for the explanation. Carefully examining an unpopulated board, I don't see any exposed copper on the traces, so I think I'm safe here. I know for sure I ran DRC based on the PCB house's specifications.
@Arsenal very interesting, I hadn't thought of that! I actually designed inrush protection into the board, but I messed up the design and had to bypass it. Reducing the wire length is unfortunately not possible (wire must be routed up a wall, across the ceiling, and down to the light fixture), but I'll work to correct my inrush protection on the next iteration.

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