Shell: an open face next to a concave edge no longer cuts the wall past it (#1495)

The pushed-out cavity is trimmed so that past an open face's plane it only reaches through the open face itself.

crates/engine/tests/shell_opening_regressions.rs

@@ -0,0 +1,58 @@
+//! A shell whose open face meets a concave edge must not cut into the wall past that edge.
+//!
+//! Lower box `[0, 25] × [0, 17.5] × [0, 35]`, top box `[7.5, 22.5] × [0, w] × [35, 42.5]` with
+//! `w ≤ 17.5`, and the shell opens the top box's left face (x = 7.5). That face's bottom edge is
+//! concave: the lower box's top runs on from it. With walls `t` thick, the cavity is
+//!
+//! - in the lower box: `[t, 25 − t] × [t, 17.5 − t] × [t, 35 − t]`
+//! - in the top box, out to the open face: `[7.5, 22.5 − t] × [t, w − t] × [35 − t, 42.5 − t]`
+//!
+//! The shell's volume is the solid's volume less those two boxes. The open face used to be
+//! pushed out past the lower box's top, cutting a strip through that wall.
+use serde_json::json;
+use solidcraft_engine::Session;
+
+fn run(s: &mut Session, id: &str, p: serde_json::Value) {
+    if let Err(e) = s.execute(id, &p) {
+        panic!("{id} {p}: {e}");
+    }
+}
+
+fn shell_volume(w: f64, t: f64) -> f64 {
+    let solid = 25.0 * 17.5 * 35.0 + 15.0 * w * 7.5;
+    let lower = (25.0 - 2.0 * t) * (17.5 - 2.0 * t) * (35.0 - 2.0 * t);
+    let upper = (15.0 - t) * (w - 2.0 * t) * 7.5;
+    solid - lower - upper
+}
+
+fn shelled(w: f64, t: f64) -> Session {
+    let mut s = Session::default();
+    run(&mut s, "solid.box", json!({"height": 35.0, "length": 25.0, "width": 17.5}));
+    run(&mut s, "solid.box", json!({"corner": [7.5, 0.0, 35.0], "height": 7.5, "length": 15.0, "operation": "join", "width": w}));
+    run(&mut s, "solid.shell", json!({"faces": [[7.5, w / 2.0, 38.75]], "thickness": t}));
+    s
+}
+
+fn check(s: &Session, want: f64) {
+    let errors: Vec<_> = s.model.results.iter().filter_map(|r| r.error.clone()).collect();
+    assert!(errors.is_empty(), "{errors:?}");
+    let st = s.model.state();
+    assert_eq!(st.bodies.len(), 1, "one body");
+    let b = &st.bodies[0].body;
+    assert!(b.validity().is_empty(), "{:?}", b.validity());
+    assert_eq!(b.shell_count(), 1, "one shell");
+    let got = solidcraft_kernel::measure(b).map(|m| m.volume).unwrap_or(f64::NAN);
+    assert!((got - want).abs() < 1e-6 * want, "shell volume {got}, want {want}");
+}
+
+#[test]
+fn open_face_flush_with_the_back_keeps_the_wall_past_its_concave_edge() {
+    for t in [1.0, 1.5] {
+        check(&shelled(17.5, t), shell_volume(17.5, t));
+    }
+}
+
+#[test]
+fn open_face_inside_the_footprint_keeps_the_wall_past_its_concave_edge() {
+    check(&shelled(15.0, 1.5), shell_volume(15.0, 1.5));
+}

crates/kernel/src/polyhedron.rs

@@ -561,6 +561,14 @@ fn shell_opened(b: &Body, healed: &Body, open: &[Vec3], opened: &[usize], thickn
         Ok(c) => c,
         Err(e) => return shell_by_opening(healed, opened, thickness, margin).map_err(|_| e),
     };
+    let cavity = match opening_overreach(healed, &cavity, opened, thickness, margin) {
+        Ok(Some(trimmed)) => trimmed,
+        Ok(None) => cavity,
+        Err(e) => {
+            log::warn!("shell: could not trim the opening to the open faces ({e}); the wall next to it may be cut");
+            cavity
+        }
+    };
     let r = crate::ops::boolean(healed, &cavity, crate::BoolOp::Cut);
     if r.is_err()
         && let Ok(x) = shell_by_opening(healed, opened, thickness, margin)
@@ -605,6 +613,83 @@ fn shell_opened(b: &Body, healed: &Body, open: &[Vec3], opened: &[usize], thickn
 /// A shell made from the cavity with every face moved in by the thickness (open faces too),
 /// joined with each open face's moved copy swept out through the body. No history: the
 /// opening's walls, swept from the cavity's edges, come from nothing of `b`.
+/// The cavity with each open face pushed out (`cavity`), trimmed so that beyond an open face's
+/// plane it only reaches through the open face itself; `None` when it already does.
+///
+/// The pushed-out face carries the cavity past every edge of the open face. Past a convex edge
+/// that is outside the body, but past a concave one (a box on a box, its side face open where it
+/// meets the lower box's top) it runs on into the neighbouring wall and cuts a strip through it,
+/// as wide as the push. The trimmed cavity is the shell's cavity with every face moved in,
+/// together with the pushed-out cavity's parts that are on the body's side of every open face's
+/// plane or in front of that open face.
+fn opening_overreach(healed: &Body, cavity: &Body, opened: &[usize], thickness: f64, margin: f64) -> Result<Option<Body>> {
+    let size = healed.size();
+    let tol = size * 1e-6 + 1e-9;
+    let faces: Vec<mt::Face> = healed.solid.face_iter().cloned().collect();
+    // Each open face's plane (outward normal, offset) and its triangles.
+    let mesh = healed.tessellate((size * 1e-3).max(1e-3))?;
+    let mut open: Vec<(&mt::Face, Vec3, f64, Vec<[Vec3; 3]>)> = Vec::new();
+    for fi in opened {
+        let Some(f) = faces.get(*fi) else { return Ok(None) };
+        let mt::Surface::Plane(pl) = f.oriented_surface() else { return Ok(None) };
+        let n = pl.normal();
+        let Some(n) = Vec3::new(n.x, n.y, n.z).normalized() else { return Ok(None) };
+        let d = n.dot(from_p3(pl.origin()));
+        let tris: Vec<[Vec3; 3]> =
+            mesh.triangles.iter().zip(&mesh.tri_face).filter(|(_, f)| **f as usize == *fi).filter_map(|(t, _)| mesh.tri(t)).collect();
+        if tris.is_empty() {
+            return Ok(None);
+        }
+        open.push((f, n, d, tris));
+    }
+    // Only a corner of the cavity past an open face's plane and not in front of that face can be
+    // in a wall; with none, the cavity is right as it is.
+    let overreach = cavity.solid.vertex_iter().any(|v| {
+        let q = from_p3(v.point());
+        open.iter().any(|(_, n, d, tris)| {
+            let h = n.dot(q) - d;
+            h > tol && {
+                let on = q - *n * h;
+                !tris.iter().any(|[a, b, c]| point_tri(on, *a, *b, *c) < size * 1e-4 + 1e-6)
+            }
+        })
+    });
+    if !overreach {
+        return Ok(None);
+    }
+    let closed = offset_planar(healed, |_, _| -thickness)?;
+    // Keep: on the body's side of each open plane, or in front of the open face.
+    let reach = size * 4.0;
+    let mut keep: Option<Body> = None;
+    for (f, n, d, _) in &open {
+        let c = *n * *d;
+        let mut hs = vec![HalfSpace { n: *n, d: *d }];
+        for axis in [Vec3::X, Vec3::Y, Vec3::Z] {
+            hs.push(HalfSpace { n: axis, d: axis.dot(c) + reach });
+            hs.push(HalfSpace { n: axis * -1.0, d: -axis.dot(c) + reach });
+        }
+        let (side, _) = polyhedron(&hs)?;
+        // In front of the face: its prism, from half a wall inside the body (overlapping `side`
+        // rather than touching it) to past the pushed-out face.
+        let inset = thickness * 0.5;
+        let prism = guard("shell opening prism", || {
+            let start = builder::translated(*f, v3(*n * -inset));
+            let solid: Solid = builder::tsweep(&start, v3(*n * (inset + margin * 2.0)));
+            Ok(solid)
+        })?;
+        let prism = Body::new(prism)?;
+        let k = crate::ops::boolean(&side, &prism, crate::BoolOp::Union)?.ok_or_else(|| KernelError::Failed("shell: opening".into()))?;
+        keep = Some(match keep {
+            None => k,
+            Some(acc) => crate::ops::boolean(&acc, &k, crate::BoolOp::Intersect)?.ok_or_else(|| KernelError::Failed("shell: opening".into()))?,
+        });
+    }
+    let Some(keep) = keep else { return Ok(None) };
+    let kept = crate::ops::boolean(cavity, &keep, crate::BoolOp::Intersect)?.ok_or_else(|| KernelError::Failed("shell: opening".into()))?;
+    let trimmed = crate::ops::boolean(&closed, &kept, crate::BoolOp::Union)?.ok_or_else(|| KernelError::Failed("shell: opening".into()))?;
+    Ok(Some(trimmed))
+}
+
 fn shell_by_opening(b: &Body, opened: &[usize], thickness: f64, reach: f64) -> Result<Body> {
     let closed = offset_planar(b, |_, _| -thickness)?;
     let faces: Vec<mt::Face> = closed.solid.face_iter().cloned().collect();