Curious how long did that take and what iteration made it to production? What CAD was used for prior designs? Can you give an example of a "minority layout" that your tech deemed unfavorable?
I really want to believe KiCAD is there...but when billable labor rates are $150+/hr, and a single iteration of that complexity can easily burn US$10k+/ea in one-off prototype quantities + 4-6 month slip for manufacturing, assembly, reintegration, and verification testing, all of a sudden (free == cost-effective ?) becomes a very real risk consideration...never mind that I've yet to engage a customer that was willing to subsidize my development budget based on technical decision to assume a tool risk because it makes the cost of doing business marginally cheaper for me.
One shouldn't lay all of those costs on a tool just because a design needs an iteration to be correct. That happens even with expensive tools. The only question is weather there are any hindrances to doing the design as best as the humans know how.
I really want to believe KiCAD is there...but when billable labor rates are $150+/hr, and a single iteration of that complexity can easily burn US$10k+/ea in one-off prototype quantities + 4-6 month slip for manufacturing, assembly, reintegration, and verification testing, all of a sudden (free == cost-effective ?) becomes a very real risk consideration...never mind that I've yet to engage a customer that was willing to subsidize my development budget based on technical decision to assume a tool risk because it makes the cost of doing business marginally cheaper for me.