Index

Hardware Engineering
Error Index

A public index of recurring engineering software errors, workflow failures, and AI agent failure modes across major hardware platforms, sourced from community reports.

72 errors tracked across the full indextotal est. annual cost $705,420median $9,188evidence: 4 High / 36 Medium / 32 Lowwe show our limits.

Showing 72 of 72 errors

Costliest errors

of 72
The top 12 costliest errors account for 30% of the modeled total under these filters.

Showing 72 of 72 errors

ErrorSoftwareCategoryConfidence
Users report difficult usability and the need for a more user-friendly experience.
Usability
Siemens TeamcenterPLM$18k2 days2Medium
Daily use is described as heavy and complicated, with too many steps and too many logins.
Workflow friction
Dassault 3DEXPERIENCE / ENOVIAPLM$18k2 days2Medium
A KiCad MCP bridge normalizes DRC, connectivity, and geometry into its own output format, and that normalized output can silently disagree with the native KiCad engine. The maintainer had to build seeded false-PASS and false-FAIL tests because the bridge layer cannot be trusted as engineering truth on its own.
Agent failure
kicad-mcp-pro (KiCad MCP bridge)ECAD$18k2 days1Medium
An AI-driven PCB build pipeline ran its 3D interference gate against a cached mesh from the previous board revision because the loader hard-coded the prior package path. It reported zero interferences on a board that had three real ones, including parts inside a headphone jack's moulded body.
Agent failure
pcb-skill (AI PCB build agent)Verification$18k3 days1Medium
A SolidWorks MCP bridge returned success JSON and even a normal-looking PDF export while the live document was wrong: a sketch asked for the Right plane silently landed on Front, and a macro call reported success=False with zero errors while never running. Only visual inspection inside SolidWorks itself revealed it.
Agent failure
SolidWorks MCP bridge (alisamsam/Solidworks-MCP)MCAD$18k2 days1Medium
AI PCB design output can look finished and pass every geometric DRC check while being electrically wrong: clean routing, zero DRC errors, and an amplifier with its inputs tied together, or a plausible part number with an invented pinout. DRC checks geometry, not whether the circuit works.
Agent failure
AI PCB design tools (general)ECAD$18k5 days1Low
Raw LLM-driven KiCad agents cannot be trusted to generate board and schematic files directly, because the file formats contain implicit relationships the model does not understand. The safe architecture is: the model proposes intent, deterministic tools execute, and a verification engine produces evidence.
Agent failure
LLM-driven KiCad agents (general)ECAD$18k2 days1Low
A cleanup tool that should remove only unconnected track segments deleted between 13 and 728 connected segments across six demo boards that had zero unconnected segments. DRC afterwards showed up to 196 unconnected nets.
Agent failure
mcp-server-kicad (KiCad MCP server)ECAD$18k2 days1Low
Firmware and schematic agree that one output drives the heater and another fires the Deploy 2 pyro charge, but the PCB swaps OUT3 and OUT4. A heater command would energize the pyro output, and neither ERC nor the netlist flags the swap.
Agent failure
proveskit flight_controller_board (KiCad design)ECAD$18k3 days1Low
Interface feels outdated, not user-friendly, and many tasks take too many clicks.
Usability
PTC WindchillPLM$16.8k2 days1Medium
Complex interface and lag issues are reported, especially around larger assemblies and broad feature scope.
Performance
Siemens TeamcenterPLM$16.2k2 days1Medium
Steep learning curve, unfamiliar terminology, and general complexity frustrate new teams.
Learning curve
PTC WindchillPLM$16.2k2 days2Medium
Slow performance is a recurring complaint; even simple work can take much longer than expected.
Performance
Aras InnovatorPLM$16.2k2 days2Medium
File management is called unintuitive and awful; ECN workflows require too many pages and steps.
Usability
Dassault 3DEXPERIENCE file managementPDM$15.4k3 days1Medium
Navigation and search are described as clunky, unintuitive, and difficult to learn.
Usability
Dassault 3DEXPERIENCE / ENOVIAPLM$15k2 days2Medium
PDM is described as slow, clunky, and not worth the overhead for some teams.
Performance
SOLIDWORKS PDMPDM$14.4k2 days2Medium
Remote-office use over VPN is described as laggy for opening, saving, and placing library parts.
Performance
Autodesk VaultPDM$14.4k2 days1Medium
Setup and administration are described as an absolute nightmare with weak documentation/support.
Setup & admin
Siemens TeamcenterPLM$13.5k2 days1High
When an agent fans out parallel create calls through the FreeCAD MCP bridge, the shared connection races: the first object is created even though its call reports failure, and the second object is silently never created with the status still showing healthy.
Agent failure
FreeCAD MCP bridge (neka-nat/freecad-mcp)MCAD$13.5k1 days2Medium
An engineer running Claude Code against KiCad found the agent kept repeating a stale claim of 19 DRC violations that lived on in prose docs. MCP tool summaries cannot be treated as live numbers; only DRC message text and actual exports are authoritative.
Agent failure
KiCad MCP agent stack (Claude Code + MCP servers)ECAD$13.5k1 days1Medium
A shipped SolidWorks agent skill called interference-check API methods that do not exist (InterferenceDetection, GetInterference(index), GetComponents) and called Done() before computing, so its core validation step could never complete on a real machine. The check silently never ran.
Agent failure
SolidWorks agent skill (solidworks-automation-skill)MCAD$13.5k2 days1Low
A FreeCAD MCP bridge silently ignored parameters the client materialized from JSON-Schema defaults, so box(size=20) produced a default 10mm shape. The agent believes it built the requested geometry while the model is something else entirely.
Agent failure
FreeCAD MCP bridge (blwfish/freecad-mcp)MCAD$13.5k1 days1Medium
A FreeCAD MCP bridge's autosave-before-call rewrote the active document on every tool call even with zero unsaved changes, stamping phantom diffs onto git-tracked CAD files. Agent activity pollutes version control with edits no human authored.
Agent failure
FreeCAD MCP bridge (blwfish/freecad-mcp)MCAD$13.5k0 days1Medium
A FreeCAD MCP bridge's persistent execution namespace meant that once any call bound a variable named result, every later call echoed the old value as its own output. The agent reads that output and believes its code produced a value it never computed.
Agent failure
FreeCAD MCP bridge (blwfish/freecad-mcp)MCAD$13.5k1 days1Low
A CAD agent bridge's screenshot tool refused any image over a 50KB socket frame, so every real model screenshot was dropped, and images that did fit arrived as base64 text inside JSON instead of real image blocks. The agent's only visual feedback channel was dead for production-scale models.
Agent failure
FreeCAD MCP bridge (blwfish/freecad-mcp)MCAD$13.5k1 days1Low
A scheduled engineering agent job ran green for weeks while silently doing nothing. An agent that reports an ECO as processed while the PLM write silently failed is a manufacturing defect waiting to happen, and nothing in the status channel distinguishes done from never-started.
Agent failure
Scheduled engineering agents (general)PLM$13.5k2 days1Low
ato build silently converts blind and micro vias to through vias because the Via struct has no field for via type. The build reports success while KiCad DRC errors rise from 5 to 45, and all 10 blind vias in the test design come out as through vias.
Agent failure
atopile (ato build)ECAD$13.5k2 days1Low
Checking items back in is described as far more difficult than older systems.
Workflow friction
Windchill PDMLinkPDM$13.0k2 days1Medium
A FreeCAD MCP bridge reported clean instance shutdowns as failures 100 percent of the time on Linux, because its liveness check polled immediately after signaling the process group. The agent was sent to retry or kill processes that were already gone.
Agent failure
FreeCAD MCP bridge (blwfish/freecad-mcp)MCAD$12k0 days1Low
View customization and interface access are described as a clickfest with poor direct manipulation.
Usability
Windchill PDMLinkPDM$11.5k2 days2Medium
Users call the UI outdated and the search function too exacting or ineffective.
Usability
Arena PLMPLM$10.8k1 days2Low
Saving an assembly can trigger rebuilds that break mates and randomly alter mate dimensions.
Stability
SOLIDWORKSMCAD$10.5k3 days1High
Integration with Windows Explorer is reported as unstable and a drag on SOLIDWORKS performance.
Stability
SOLIDWORKS PDMPDM$9.6k2 days1Medium
Interface is described as outdated and in need of cloud-era usability improvements.
Usability
Autodesk VaultPDM$9.6k2 days1Low
Effective setup and configuration require substantial training, especially for novices.
Setup & admin
Autodesk VaultPDM$9.6k2 days2Low
Joint-linked subassemblies become hard to maintain; geometry changes can break everything in larger assemblies.
Stability
Autodesk InventorMCAD$9.4k3 days1Medium
Large assemblies can lock up on open with the feature tree failing to populate.
Performance
SOLIDWORKSMCAD$9k2 days1High
Even simple save/check-in operations can take minutes on capable hardware.
Performance
SOLIDWORKSMCAD$9k2 days2Medium
Power and flexibility come with substantial configuration risk and expert dependence.
Setup & admin
Oracle Agile PLMPLM$9k1 days1Medium
A customer agent hit a failing tool and retried it with slightly different prompts 31,000 times overnight, burning $4,700 against a $400/month plan. The same loop with write access to CAD or PLM does not just burn budget: it can corrupt revision state, spam ECOs, or thrash a shared vault.
Agent failure
AI agent runner (general)Verification$9k1 days1Low
An ECAD routing agent's CLI reported ready even when the underlying run had terminated: InitializeCLI returned true on TERMINATED. Every experiment scored after that point was measured against a false baseline, and the false success was only caught because the team had frozen baselines to compare against.
Agent failure
freerouting self-improving routing loopVerification$9k1 days1Low
An agent bridge for Altium maps an unrecognized layer name to TOP COPPER instead of failing. A typo in a layer name can delete copper on the wrong layer while the tool reports the cleanup as done.
Agent failure
eda-agent (Altium MCP bridge)ECAD$9k2 days1Low
set_design_rules, create_netclass, and assign_net_to_class write the .kicad_pro file while KiCad has it open and report success. KiCad's next save silently reverts the changes, for example after run_drc, so the rules the agent set are gone with no warning.
Agent failure
Konnect (KiCad MCP bridge)ECAD$9k1 days1Low
Copy Design is described as big, clunky, and slow even by experienced Vault users.
Workflow friction
Autodesk VaultPDM$8.6k1 days1Low
Installation, vault setup, and configuration are technical enough to require IT or a dedicated admin.
Setup & admin
SOLIDWORKS PDMPDM$8.4k1 days1Medium
Drawing/detailing workflows are described as slow, awkward, and aggravating.
Performance
PTC CreoMCAD$7.5k2 days1Medium
General UI/UX is described as confusing and hostile for routine work.
Usability
Autodesk Fusion 360MCAD$7.2k2 days1Low
Drawing toolset is described as missing basic drafting capabilities and mark-up controls.
Usability
OnshapeMCAD$6.8k2 days2Medium
run_erc returned 0 violations, 0 warnings, and 0 errors for an ERC report it could not parse. A parse failure reads as a clean board.
Agent failure
Konnect (KiCad MCP bridge)Verification$6.8k1 days1Low
Learning curve is described as vertical; selection logic and menus feel unnecessarily complex.
Usability
Siemens NXMCAD$6k2 days1Low
Cloud-first file model makes local file control, rename/move/backup workflows feel alien and risky.
Usability
Autodesk Fusion 360MCAD$5.4k1 days1Medium
IDE is described as unpredictable, quirky, and one of the worst embedded IDE experiences.
Stability
STM32CubeIDEFirmware$5.4k2 days1Medium
Constant crashing and configurator failures are reported to burn significant project time.
Stability
MPLAB XFirmware$5.4k2 days2High
Large-assembly handling and richer 3D communication workflows are described as limited compared with expectations.
Performance
OnshapeMCAD$4.5k1 days2Low
Code editor is described as slow, bloated, and basically an Eclipse reskin.
Performance
STM32CubeIDEFirmware$4.5k2 days1Low
Editor is considered poor, compatibility is Windows-centric, and project setup can be painful.
Usability
Keil uVisionFirmware$3.8k2 days3Low
UI/UX is repeatedly described as rubbish, clunky, and rooted in legacy design patterns.
Usability
Cadence OrCAD / AllegroECAD$3.6k2 days2Medium
Mode-heavy interactions and inconsistent property editing create cognitive overhead.
Workflow friction
Cadence OrCAD / AllegroECAD$3.6k2 days1Medium
Arduino IDE is repeatedly described as lacking standard IDE capabilities and being unsuitable for serious workflows.
Usability
Arduino IDEFirmware$3.6k2 days3Low
Custom board support requires manual JSON/config work and poor documentation.
Setup & admin
PlatformIOFirmware$3.4k2 days2Low
Interactive routing creates unwanted micro-segments and awkward paths that take time to clean up.
Usability
KiCadECAD$3.4k2 days2Medium
Generated makefiles and toolchain coupling force teams to keep the IDE in build pipelines.
Workflow friction
MPLAB XFirmware$3.2k1 days1Low
Users report noticeable lag even in schematic operations like moving labels and wires.
Performance
Cadence OrCAD / AllegroECAD$3k2 days1Medium
Grid snap and move commands can disconnect items or reposition them in unwanted ways.
Usability
KiCadECAD$3k2 days2Low
GUI lag, occasional freezes, and sluggish editor switching interrupt concentration.
Performance
KiCadECAD$2.9k2 days2Medium
Library management and schematic-layout switching are described as bad and slow.
Usability
Autodesk EAGLE / Fusion ElectronicsECAD$2.9k2 days2Low
Package installation and internet/proxy dependency can block even first-time setup for hours.
Setup & admin
STM32CubeMX / STM32CubeIDEFirmware$2.7k1 days1Medium
PlatformIO support for Zephyr quietly ended, creating surprise workflow dead ends.
Platform & ecosystem
PlatformIO + ZephyrFirmware$2.3k1 days1Medium
Newer UI layers are called buggy and still dependent on legacy tools for non-trivial boards.
Stability
Cadence OrCAD X / PrestoECAD$2.2k1 days1Medium
Confusing UX and poor high-DPI behavior make text unreadable and controls awkward.
Usability
Autodesk EAGLEECAD$1.8k1 days2Low
Linux/Wayland users report crash behavior and segmentation faults.
Stability
STM32CubeIDEFirmware$1.8k1 days1Low
Wayland/NVIDIA users report graphical glitches, flicker, or instability.
Platform & ecosystem
KiCadECAD$1.4k1 days1Low