STEP export: unique ids, plain curves, right revolution senses; seams on split faces

Vendored truck-stepio (writer only): an intersection curve's second surface
was written at the first one's id (duplicate ids for every boolean edge),
and revolved surfaces lost their orientation (the modeling-surface sense was
always true; inverted or mirrored revolutions came out inside out). Export
now writes intersection edges as C1 cubic B-splines through exact points,
so files carry plain 3D curves and no redundant surfaces.

Vendored truck-meshalgo: hinted parameter searches that run off a B-spline's
domain are rejected or clamped (meshing their grid never finished).

STEP import: straight revolution profiles are bounded in the meridian plane
and stop at the axis; loops on revolutions start away from the axis; face
extents include edge end points. Edges between pieces of one split surface
draw as seams.

kernel::step_validate checks a STEP file (duplicate ids, dangling
references, dense numbering); the oracle replay now exports every rebuilt
part, validates it and re-imports it with no warnings and the same volume
(all 32 rebuildable cases pass).

Co-Authored-By: Claude Opus 5.5 <[email protected]>
Claude-Session: https://claude.ai/code/session_01AS5Tn3xieewUSg3uxrMVdL

crates/kernel/src/step.rs

@@ -1,8 +1,67 @@
+use truck_modeling as mt;
 use truck_stepio::out;
 
 use crate::body::Body;
 use crate::{KernelError, Result, guard};
 
+/// Intersection-curve edges (from booleans) as cubic B-splines through the exact curve: STEP
+/// readers get plain 3D geometry that lies on both faces, and the file does not repeat the two
+/// surfaces for every such edge.
+fn plain_curves(b: &Body) -> mt::Solid {
+    let s = b.deep_copy();
+    let size = b.size();
+    let mut seen = std::collections::HashSet::new();
+    for e in s.edge_iter() {
+        if !seen.insert(e.id()) {
+            continue;
+        }
+        if let mt::Curve::IntersectionCurve(ic) = e.curve()
+            && let Some(c) = hermite_through(&ic, size * 1e-4)
+        {
+            e.set_curve(mt::Curve::BSplineCurve(c));
+        }
+    }
+    s
+}
+
+/// A C¹ cubic B-spline through exact points of `c` spaced so that chords deviate at most `tol`
+/// (Catmull–Rom tangents over chord length; the cubic is far closer than the chords).
+fn hermite_through<C>(c: &C, tol: f64) -> Option<mt::BSplineCurve<mt::Point3>>
+where
+    C: mt::ParametricCurve<Point = mt::Point3, Vector = mt::Vector3> + mt::BoundedCurve + mt::ParameterDivision1D<Point = mt::Point3>,
+{
+    use mt::{InnerSpace, MetricSpace};
+    let (_, pts) = c.parameter_division(c.range_tuple(), tol);
+    let pts: Vec<mt::Point3> = pts.into_iter().fold(Vec::new(), |mut v: Vec<mt::Point3>, p| {
+        if v.last().is_none_or(|q| q.distance(p) > tol * 1e-3) {
+            v.push(p);
+        }
+        v
+    });
+    let n = pts.len().checked_sub(1).filter(|n| *n >= 1 && *n < 1_000_000)?;
+    let mut u = vec![0.0; n + 1];
+    for i in 1..=n {
+        u[i] = u[i - 1] + pts[i].distance(pts[i - 1]);
+    }
+    let tangent = |i: usize| {
+        let (a, b) = (i.saturating_sub(1), (i + 1).min(n));
+        (pts[b] - pts[a]) / (u[b] - u[a])
+    };
+    let mut ctrl = vec![pts[0]];
+    let mut knots = vec![u[0]; 4];
+    for i in 0..n {
+        let h = u[i + 1] - u[i];
+        ctrl.push(pts[i] + tangent(i) * (h / 3.0));
+        ctrl.push(pts[i + 1] - tangent(i + 1) * (h / 3.0));
+        ctrl.push(pts[i + 1]);
+        knots.extend(std::iter::repeat_n(u[i + 1], if i + 1 == n { 4 } else { 3 }));
+    }
+    if ctrl.iter().any(|p| !(p.x.is_finite() && p.y.is_finite() && p.z.is_finite())) || tangent(0).magnitude() == 0.0 {
+        return None;
+    }
+    mt::BSplineCurve::try_new(mt::KnotVec::from(knots), ctrl).ok()
+}
+
 /// STEP (ISO 10303-21) text for the given bodies.
 pub fn step_export(bodies: &[&Body], system: &str) -> Result<String> {
     if bodies.is_empty() {
@@ -12,7 +71,7 @@ pub fn step_export(bodies: &[&Body], system: &str) -> Result<String> {
         b.require_brep("STEP export")?;
     }
     guard("step export", || {
-        let cs: Vec<_> = bodies.iter().map(|b| b.solid.compress()).collect();
+        let cs: Vec<_> = bodies.iter().map(|b| plain_curves(b).compress()).collect();
         let models: out::StepModels<_, _, _> = cs.iter().collect();
         let header = out::StepHeaderDescriptor { organization_system: system.to_owned(), ..Default::default() };
         Ok(out::CompleteStepDisplay::new(models, header).to_string())