Sheet metal: machine a hole feature's drills in one pass, keep cuts after a text cut (#1979) (#1980)

Thanks @NOWN-DEV.

crates/doc/src/eval.rs

@@ -2660,6 +2660,23 @@ fn sheet_hole_cut(
     let mut handled: Vec<String> = Vec::new();
     // Noted only when every tool was machined here.
     let mut parted = None;
+    // Many plain drills along one axis (a hole on each of a pattern's points): all in one pass.
+    let prisms: Option<Vec<more::PrimitivePrism>> = tools.iter().map(|(_, prism)| *prism).collect();
+    if let Some(prisms) = prisms {
+        match more::sheet_drill_cuts(f, st, &prisms, &mut parted) {
+            Ok(Some(done)) => {
+                if let Some(note) = parted {
+                    append_warning(warning, note);
+                }
+                return Ok(done);
+            }
+            // Not all of them that way, or refused at once: one by one, from the model as it was.
+            Ok(None) | Err(_) => {
+                (st.sheets, st.bodies) = saved.clone();
+                parted = None;
+            }
+        }
+    }
     for (tool, prism) in tools {
         let tool = &tool.body;
         let done = match prism {

crates/doc/src/eval_more.rs

@@ -5,7 +5,7 @@ use super::*;
 use crate::EmbossFace;
 use crate::apply_point;
 use crate::sheet;
-use solidcraft_geom::{Loop2, Seg2};
+use solidcraft_geom::{Aabb3, Loop2, Seg2};
 
 pub(super) fn eval(doc: &Document, vals: &BTreeMap<String, Value>, f: &Feature, st: &mut ModelState) -> Result<()> {
     match &f.kind {
@@ -833,11 +833,20 @@ pub(super) fn sheet_primitive_cut(
     if !matches!(operation, Operation::Cut | Operation::Intersect) || !any_eligible_sheet(f, st, &[]) {
         return Ok(Vec::new());
     }
-    // The first sheet the primitive meets decides the machining direction.
+    // The first sheet the primitive meets decides the machining direction. Sheets clear of it
+    // by their boxes are passed over; the one sheet left needs no boolean to show it is met (that
+    // boolean came out empty against a sheet carrying a label's cut-outs, and the hole was then
+    // cut into the solid without a place in the flat pattern).
+    let tool_box = body_box(tool);
+    let near: Vec<&sheet::SheetBody> = st
+        .sheets
+        .iter()
+        .filter(|sh| sheet_eligible(f, st, &[], sh) && st.body(&sh.body).is_some_and(|mb| !boxes_apart(&mesh_box(mb), &tool_box)))
+        .collect();
     let mut normal = None;
-    for sh in st.sheets.iter().filter(|sh| sheet_eligible(f, st, &[], sh)) {
+    for sh in &near {
         if let Some(mb) = st.body(&sh.body)
-            && kernel::boolean(&mb.body, tool, kernel::BoolOp::Intersect)?.is_some()
+            && (near.len() == 1 || kernel::boolean(&mb.body, tool, kernel::BoolOp::Intersect)?.is_some())
         {
             normal = Some(match prism {
                 PrimitivePrism::Cylinder { axis, .. }
@@ -895,6 +904,70 @@ pub(super) fn sheet_bore_cut(f: &Feature, st: &mut ModelState, prism: PrimitiveP
     Ok(Some(handled))
 }
 
+/// The most hole tools machined in one pass by [`sheet_drill_cuts`].
+const MAX_DRILLS_AT_ONCE: usize = 1000;
+
+/// A hole feature's straight drills (`prisms`, all along one axis), machined into the sheets in
+/// one pass for each depth they share: one rebuild of the sheet and of its flat pattern for all
+/// of them, rather than one per drill, each on a sheet machined by the ones before.
+/// The drills are the cut-outs and pockets [`sheet_primitive_cut`] makes of them one at a time.
+/// None when they can't all be taken this way (they are not all cylinders along one axis that
+/// every sheet they may machine takes square, or a sheet keeps one some other way): the caller
+/// then puts the model back and drills them one by one.
+pub(super) fn sheet_drill_cuts(
+    f: &Feature,
+    st: &mut ModelState,
+    prisms: &[PrimitivePrism],
+    warning: &mut Option<String>,
+) -> Result<Option<Vec<String>>> {
+    if prisms.len() < 2 || prisms.len() > MAX_DRILLS_AT_ONCE || !any_eligible_sheet(f, st, &[]) {
+        return Ok(None);
+    }
+    let Some(PrimitivePrism::Cylinder { base: base0, axis: axis0, .. }) = prisms.first().copied() else { return Ok(None) };
+    let Some(axis) = axis0.normalized() else { return Ok(None) };
+    let Some(plane) = Plane::from_normal(base0, axis) else { return Ok(None) };
+    // Every sheet the drills may machine takes them square: along its normal, or (folded) square
+    // to one of its panels, as a single drill would be taken.
+    for sh in st.sheets.iter().filter(|sh| sheet_eligible(f, st, &[], sh)) {
+        let square = sh.frame.normal().cross(axis).len() <= 1e-12 || (!sh.flat && !sh.parallel_panels(&plane).is_empty());
+        if !square {
+            return Ok(None);
+        }
+    }
+    // Each drill in the one plane: its circle, and its depth interval along the axis.
+    let mut groups: Vec<((f64, f64), Vec<Region2>)> = Vec::new();
+    for prism in prisms {
+        let PrimitivePrism::Cylinder { base, axis: a, radius, height } = *prism else { return Ok(None) };
+        let Some(a) = a.normalized() else { return Ok(None) };
+        if a.cross(axis).len() > 1e-12 || ![base.x, base.y, base.z, radius, height].iter().all(|v| v.is_finite()) || !(radius > 0.0) {
+            return Ok(None);
+        }
+        let (sense, at) = (a.dot(axis).signum(), (base - base0).dot(axis));
+        let (e0, e1) = (at + sense * height.min(0.0), at + sense * height.max(0.0));
+        let interval = (e0.min(e1), e0.max(e1));
+        let circle = Region2 { outer: Loop2::circle(plane.to_local(base), radius), holes: vec![] };
+        let same = |(lo, hi): (f64, f64)| (lo - interval.0).abs() <= 1e-9 * (1.0 + lo.abs()) && (hi - interval.1).abs() <= 1e-9 * (1.0 + hi.abs());
+        match groups.iter_mut().find(|(i, _)| same(*i)) {
+            Some((_, regions)) => regions.push(circle),
+            None => groups.push((interval, vec![circle])),
+        }
+    }
+    let mut handled: Vec<String> = Vec::new();
+    for ((lo, hi), regions) in groups {
+        let tools = kernel::extrude(&plane, &regions, lo, hi)?;
+        let done = sheet_prism_cut(f, st, &plane, &regions, Operation::Cut, &tools, &[], None, false, &[], warning)?;
+        if done.is_empty() {
+            return Ok(None);
+        }
+        for name in done {
+            if !handled.contains(&name) {
+                handled.push(name);
+            }
+        }
+    }
+    Ok(Some(handled))
+}
+
 /// A primitive tool's exact geometry, for [`sheet_primitive_cut`].
 #[derive(Clone, Copy, Debug)]
 pub(super) enum PrimitivePrism {
@@ -1003,6 +1076,9 @@ fn sheet_prism_cut(
     } else {
         Vec::new()
     };
+    // Boxes around the tools: a tool clear of a bend by its box needs no boolean to show it (a
+    // label's letters against every bend and flange of a tray).
+    let tool_boxes: Vec<Option<Aabb3>> = tools.iter().map(body_box).collect();
     let mut plans = Vec::new();
     let mut notes = Vec::new();
     'sheets: for original in &st.sheets {
@@ -1018,12 +1094,16 @@ fn sheet_prism_cut(
             plans.push((sh.body.clone(), Some((sh, mb.body.clone()))));
             continue;
         }
-        if !sh.flat && !sh.flanges.is_empty() && !super::sheet_boolean_changes(&mb.body, tools, operation)? {
-            plans.push((sh.body.clone(), Some((sh, mb.body.clone()))));
-            continue;
-        }
+        // No 3D boolean of each tool with the whole folded sheet first: the flat machining below
+        // is exact, and a cut that machines nothing there is checked against the solid after it.
+        // (That boolean cost each label hundreds of milliseconds, and against a sheet already
+        // carrying a label's cut-outs it came out empty: the next cut was dropped.)
         for bends in sh.unmodeled_solids(plane)? {
-            for tool in tools {
+            let bends_box = body_box(&bends);
+            for (tool, tool_box) in tools.iter().zip(&tool_boxes) {
+                if boxes_apart(&bends_box, tool_box) {
+                    continue;
+                }
                 if kernel::boolean(&bends, tool, kernel::BoolOp::Intersect)?.is_some() {
                     return Err(DocError::Invalid(
                         "this machining intersects a folded bend or a nonparallel panel; unfold the sheet before machining that material".into(),
@@ -1190,6 +1270,31 @@ fn sheet_prism_cut(
     Ok(handled)
 }
 
+/// A box around `body`, grown past its mesh's deflection from the exact faces (and a hair
+/// more): bodies whose boxes are apart do not meet. None when it can't be worked out.
+fn body_box(body: &Body) -> Option<Aabb3> {
+    let tol = (body.size() * 1e-3).max(1e-4);
+    padded_box(&body.tessellate(tol).ok()?, tol)
+}
+
+/// [`body_box`] of a model body, from the mesh it keeps.
+fn mesh_box(mb: &ModelBody) -> Option<Aabb3> {
+    padded_box(&mb.mesh(), mb.display_tol())
+}
+
+fn padded_box(mesh: &solidcraft_geom::Mesh, tol: f64) -> Option<Aabb3> {
+    let b = mesh.bounds();
+    let pad = 2.0 * tol + 1e-6;
+    let pad = Vec3::new(pad, pad, pad);
+    (!b.is_empty() && b.min.is_finite() && b.max.is_finite()).then(|| Aabb3 { min: b.min - pad, max: b.max + pad })
+}
+
+/// Whether two boxes are known to be apart (an unknown box is never apart).
+fn boxes_apart(a: &Option<Aabb3>, b: &Option<Aabb3>) -> bool {
+    let (Some(a), Some(b)) = (a, b) else { return false };
+    a.max.x < b.min.x || b.max.x < a.min.x || a.max.y < b.min.y || b.max.y < a.min.y || a.max.z < b.min.z || b.max.z < a.min.z
+}
+
 /// A cut's note on the pieces it parted from the base of `sh` (see
 /// [`sheet::SheetBody::parted_from_base`]; `material` is the sheet's flat material after the cut,
 /// `before` the sheet before it): how many, their area and where they lie in the flat pattern.

crates/doc/src/sheet.rs

@@ -1139,11 +1139,22 @@ impl SheetBody {
             cuts.push(fitted_region(&pocket)?);
         }
         let cuts = material_union(cuts, work)?;
+        let cut_boxes = cuts.iter().map(|c| loop_box(&c.outer)).collect::<Result<Vec<_>>>()?;
         let mut out = Vec::new();
         let mut points = 0usize;
         for (piece, region) in pieces {
             let panel = fitted_region(&planar_region(&region)?)?;
-            let material = if cuts.is_empty() { vec![panel] } else { material_boolean(&[panel], &cuts, kernel::BoolOp::Cut, work)? };
+            // Each piece meets only the cut-outs near it: arranging every cut-out of the sheet (a
+            // label's letters on its base) against each flange and bend zone too would charge the
+            // budget for all of them once per piece.
+            let (lo, hi) = loop_box(&panel.outer)?;
+            let near: Vec<Region2> = cuts
+                .iter()
+                .zip(&cut_boxes)
+                .filter(|(_, (a, b))| a.x <= hi.x && b.x >= lo.x && a.y <= hi.y && b.y >= lo.y)
+                .map(|(c, _)| c.clone())
+                .collect();
+            let material = if near.is_empty() { vec![panel] } else { material_boolean(&[panel], &near, kernel::BoolOp::Cut, work)? };
             for region in material {
                 points = points.saturating_add(region_complexity(std::slice::from_ref(&region))?.1);
                 if points > MAX_FLAT_POINTS || out.len() >= MAX_FLAT_PIECES {
@@ -1545,6 +1556,9 @@ impl SheetBody {
     }
 
     fn machine_pockets(&self, mut body: Body, work: &mut FlatWork) -> Result<Body> {
+        if self.pockets.is_empty() {
+            return Ok(body);
+        }
         if self.pockets.len() > 1000 {
             return Err(flat_budget_error());
         }

crates/engine/src/cmd/sheet.rs

@@ -893,6 +893,10 @@ fn export_bend_table(s: &mut Session, p: &Value) -> Result<Value> {
 #[path = "sheet_tests.rs"]
 mod tests;
 
+#[cfg(test)]
+#[path = "sheet_batch_cuts_tests.rs"]
+mod batch_cuts_tests;
+
 #[cfg(test)]
 #[path = "sheet_convert_tests.rs"]
 mod convert_tests;

crates/engine/src/cmd/sheet_batch_cuts_tests.rs

@@ -0,0 +1,204 @@
+//! Many cuts through one sheet: a hole feature's drills machined in one pass, labels in one
+//! sketch or one feature each, all keeping the geometry and flat pattern of cutting them one by one.
+
+use serde_json::{Value, json};
+
+use crate::Session;
+
+fn run(s: &mut Session, id: &str, p: Value) -> Value {
+    match s.execute(id, &p) {
+        Ok(v) => v,
+        Err(e) => panic!("{id} {p}: {e}"),
+    }
+}
+
+fn volume(s: &mut Session) -> f64 {
+    run(s, "inspect.measure", json!({}))["total"]["volume_mm3"].as_f64().unwrap_or(f64::NAN)
+}
+
+/// A `w` x `h` tray of 2.5 mm sheet: a base flange on XY with a 15 mm flange on each edge.
+fn tray(s: &mut Session, w: f64, h: f64) {
+    run(s, "sketch.create", json!({"plane": "XY", "name": "Base"}));
+    run(s, "sketch.rectangle.two_point", json!({"p0": [0, 0], "p1": [w, h]}));
+    run(s, "sketch.finish", json!({}));
+    run(s, "sheet.flange", json!({"sketch": "Base"}));
+    let edges = json!([[w / 2.0, h, 2.5], [w, h / 2.0, 2.5], [w / 2.0, 0, 2.5], [0, h / 2.0, 2.5]]);
+    run(s, "sheet.flange", json!({"edges": edges, "height": 15}));
+}
+
+fn through_cut(s: &mut Session, sketch: &str) {
+    run(s, "solid.extrude", json!({"sketch": sketch, "through_all": true, "direction": "symmetric", "operation": "cut"}));
+}
+
+/// A label cut on its own: one sketch, one cut.
+fn label_cut(s: &mut Session, name: &str, text: &str, at: [f64; 2]) {
+    run(s, "sketch.create", json!({"plane": "XY", "name": name}));
+    run(s, "sketch.text", json!({"text": text, "at": at, "height": 6}));
+    run(s, "sketch.finish", json!({}));
+    through_cut(s, name);
+}
+
+/// The labels in one sketch, cut at once.
+fn labels_cut(s: &mut Session, labels: &[(String, [f64; 2])]) {
+    run(s, "sketch.create", json!({"plane": "XY", "name": "Labels"}));
+    for (text, at) in labels {
+        run(s, "sketch.text", json!({"text": text, "at": at, "height": 6}));
+    }
+    run(s, "sketch.finish", json!({}));
+    through_cut(s, "Labels");
+}
+
+/// One hole feature drilling at every point (one sketch of points).
+fn holes_at_once(s: &mut Session, points: &[[f64; 2]]) {
+    run(s, "sketch.create", json!({"plane": "XY", "name": "HolePoints"}));
+    for p in points {
+        run(s, "sketch.point", json!({"point": p}));
+    }
+    run(s, "sketch.finish", json!({}));
+    run(s, "solid.hole", json!({"sketch": "HolePoints", "diameter": 4}));
+}
+
+/// A hole feature for each point, drilled into the base's top face.
+fn holes_one_by_one(s: &mut Session, points: &[[f64; 2]]) {
+    for p in points {
+        run(s, "solid.hole", json!({"position": [p[0], p[1], 2.5], "diameter": 4}));
+    }
+}
+
+fn polyline(v: &Value) -> Vec<[f64; 2]> {
+    v.as_array().map(|a| a.iter().map(|p| [p[0].as_f64().unwrap_or(f64::NAN), p[1].as_f64().unwrap_or(f64::NAN)]).collect()).unwrap_or_default()
+}
+
+fn area(p: &[[f64; 2]]) -> f64 {
+    let n = p.len();
+    (0..n).map(|i| p[i][0] * p[(i + 1) % n][1] - p[(i + 1) % n][0] * p[i][1]).sum::<f64>() / 2.0
+}
+
+fn sorted_loops(v: &Value) -> Vec<Vec<[f64; 2]>> {
+    let mut loops: Vec<Vec<[f64; 2]>> = v.as_array().map(|a| a.iter().map(polyline).collect()).unwrap_or_default();
+    loops.sort_by(|a, b| {
+        let (a, b) = (a.first().copied().unwrap_or_default(), b.first().copied().unwrap_or_default());
+        a[0].total_cmp(&b[0]).then(a[1].total_cmp(&b[1]))
+    });
+    loops
+}
+
+/// The flat pattern's outline loops and cut-outs (each a polyline, ordered by where they start,
+/// so loops made in another order compare alike) and the area they enclose.
+fn flat(s: &mut Session) -> (Vec<Vec<[f64; 2]>>, f64) {
+    let f = run(s, "sheet.flat_pattern", json!({}));
+    let mut loops = sorted_loops(&f["outline"]);
+    let cutouts = sorted_loops(&f["cutouts"]);
+    let enclosed = loops.iter().map(|l| area(l).abs()).sum::<f64>() - cutouts.iter().map(|c| area(c).abs()).sum::<f64>();
+    loops.extend(cutouts);
+    (loops, enclosed)
+}
+
+fn cutout_count(s: &mut Session) -> usize {
+    run(s, "sheet.flat_pattern", json!({}))["cutouts"].as_array().map_or(0, Vec::len)
+}
+
+/// The same volume (within a millionth) and the same flat pattern (its material area within a
+/// millionth, every point of its outline and cut-outs within 1e-6 mm).
+fn assert_same(a: &mut Session, b: &mut Session) {
+    let (va, vb) = (volume(a), volume(b));
+    assert!((va - vb).abs() <= 1e-6 * va.abs(), "volume {va} vs {vb}");
+    let (la, ma) = flat(a);
+    let (lb, mb) = flat(b);
+    assert!(ma.is_finite() && (ma - mb).abs() <= 1e-6 * ma.abs().max(1.0), "flat area {ma} vs {mb}");
+    let close = |p: &[[f64; 2]], q: &[[f64; 2]]| {
+        p.len() == q.len() && p.iter().zip(q).all(|(x, y)| (x[0] - y[0]).abs() <= 1e-6 && (x[1] - y[1]).abs() <= 1e-6)
+    };
+    assert_eq!(la.len(), lb.len(), "flat loop count");
+    for (x, y) in la.iter().zip(&lb) {
+        assert!(close(x, y), "flat loop differs: {:?} vs {:?}", x.first(), y.first());
+    }
+}
+
+fn hole_grid(n: usize, columns: usize, at: [f64; 2], pitch: f64) -> Vec<[f64; 2]> {
+    (0..n).map(|i| [at[0] + (i % columns) as f64 * pitch, at[1] + (i / columns) as f64 * pitch]).collect()
+}
+
+#[test]
+fn a_hole_feature_drills_a_sheet_in_one_pass_like_holes_one_by_one() {
+    let points = hole_grid(12, 6, [15.0, 20.0], 15.0);
+    let (mut once, mut each) = (Session::default(), Session::default());
+    tray(&mut once, 120.0, 80.0);
+    tray(&mut each, 120.0, 80.0);
+    let before = volume(&mut once);
+    holes_at_once(&mut once, &points);
+    holes_one_by_one(&mut each, &points);
+    // Each hole takes π r² t from the base (the measure follows the walls' facets).
+    let want = before - 12.0 * std::f64::consts::PI * 4.0 * 2.5;
+    assert!((volume(&mut once) - want).abs() < 1e-5 * want, "{} {want}", volume(&mut once));
+    assert_eq!(cutout_count(&mut once), 12);
+    assert_same(&mut once, &mut each);
+}
+
+/// A second cut after a text cut was dropped without a word, and a hole after it missed the flat
+/// pattern: the 3D test whether their tools met the sheet came out empty against the sheet
+/// rebuilt with the letters' cut-outs.
+#[test]
+fn a_cut_after_a_text_cut_still_cuts() {
+    let mut s = Session::default();
+    tray(&mut s, 120.0, 80.0);
+    label_cut(&mut s, "Label", "AB", [15.0, 50.0]);
+    let before = volume(&mut s);
+    run(&mut s, "sketch.create", json!({"plane": "XY", "name": "Slot"}));
+    run(&mut s, "sketch.rectangle.two_point", json!({"p0": [70, 20], "p1": [90, 30]}));
+    run(&mut s, "sketch.finish", json!({}));
+    let r = run(&mut s, "solid.extrude", json!({"sketch": "Slot", "through_all": true, "direction": "symmetric", "operation": "cut"}));
+    assert_eq!(r["changed_bodies"], json!(["Body1"]), "{r}");
+    let want = before - 20.0 * 10.0 * 2.5;
+    assert!((volume(&mut s) - want).abs() < 1e-6 * want, "{} {want}", volume(&mut s));
+    assert_eq!(cutout_count(&mut s), 3, "A, B and the slot");
+    // A hole drilled after it is a cut-out of the flat pattern too (it was cut into the solid
+    // only, so unfolding would have lost it).
+    run(&mut s, "solid.hole", json!({"position": [100, 60, 2.5], "diameter": 4}));
+    assert_eq!(cutout_count(&mut s), 4, "A, B, the slot and the hole");
+}
+
+#[test]
+fn labels_in_one_sketch_and_holes_in_one_feature_match_cutting_them_one_by_one() {
+    let labels: Vec<(String, [f64; 2])> = (0..3).map(|i| (format!("A{i}"), [15.0 + 30.0 * i as f64, 55.0])).collect();
+    let points = hole_grid(6, 6, [15.0, 20.0], 15.0);
+    let (mut once, mut each) = (Session::default(), Session::default());
+    tray(&mut once, 120.0, 80.0);
+    tray(&mut each, 120.0, 80.0);
+    labels_cut(&mut once, &labels);
+    holes_at_once(&mut once, &points);
+    for (i, (text, at)) in labels.iter().enumerate() {
+        label_cut(&mut each, &format!("Label{i}"), text, *at);
+    }
+    holes_one_by_one(&mut each, &points);
+    assert_same(&mut once, &mut each);
+}
+
+/// The full size: a flanged sheet with 10 labels and 50 holes, cut at once and one by one.
+/// `cargo test --release -p solidcraft-engine --lib sheet_many_cuts_benchmark -- --ignored --nocapture`
+#[test]
+#[ignore = "benchmark: run with --release --ignored --nocapture"]
+fn sheet_many_cuts_benchmark() {
+    let labels: Vec<(String, [f64; 2])> =
+        (0..10).map(|i| (format!("AB{i}"), [20.0 + 55.0 * (i % 5) as f64, if i < 5 { 150.0 } else { 170.0 }])).collect();
+    let points = hole_grid(50, 10, [20.0, 30.0], 20.0);
+    let time = |f: &mut dyn FnMut()| {
+        let t = std::time::Instant::now();
+        f();
+        t.elapsed().as_secs_f64() * 1000.0
+    };
+    let (mut once, mut each) = (Session::default(), Session::default());
+    tray(&mut once, 300.0, 200.0);
+    tray(&mut each, 300.0, 200.0);
+    let labels_once = time(&mut || labels_cut(&mut once, &labels));
+    let holes_once = time(&mut || holes_at_once(&mut once, &points));
+    let labels_each = time(&mut || {
+        for (i, (text, at)) in labels.iter().enumerate() {
+            label_cut(&mut each, &format!("Label{i}"), text, *at);
+        }
+    });
+    let holes_each = time(&mut || holes_one_by_one(&mut each, &points));
+    println!("labels: one sketch {labels_once:.0} ms, one feature each {labels_each:.0} ms");
+    println!("holes: one feature {holes_once:.0} ms, one feature each {holes_each:.0} ms");
+    assert_same(&mut once, &mut each);
+}