From 35ac9569dca3cc66b887677750ab08464f86b685 Mon Sep 17 00:00:00 2001
From: bherbruck <brennen.herbruck@gmail.com>
Date: Thu, 8 Oct 2026 14:19:29 +0000
Subject: [PATCH] Holes as deep as the material: a drilled hole whose drill
 point would start exactly on the exit face is cut through (QA: depth = plate
 thickness failed with coincident faces on curved bodies)

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01AS5Tn3xieewUSg3uxrMVdL
---
 crates/doc/src/eval.rs     |  8 +++++++-
 crates/engine/src/tests.rs | 27 +++++++++++++++++++++++++++
 2 files changed, 34 insertions(+), 1 deletion(-)

diff --git a/crates/doc/src/eval.rs b/crates/doc/src/eval.rs
index 792e3f83..1d17c249 100644
--- a/crates/doc/src/eval.rs
+++ b/crates/doc/src/eval.rs
@@ -1189,7 +1189,13 @@ fn hole_tools(
         HoleKind::Simple => tools.push(cyl(r, bottom, top)?),
         HoleKind::Drilled { tip_angle } => {
             let half = val(vals, tip_angle, Kind::Angle)? / 2.0;
-            if depth.is_some() && half > 1e-3 && half < std::f64::consts::FRAC_PI_2 {
+            // A hole exactly as deep as the material: the point is in the air past the exit
+            // face, which would lie on the drill point's shoulder (a through hole, as drilled).
+            let at = |h: f64| *position + dir * (-h);
+            let eps = size * 1e-6;
+            let solid_at = |h: f64| st.bodies.iter().any(|b| b.body.contains(at(h)));
+            let exits_at_shoulder = solid_at(bottom + eps) && !solid_at(bottom - eps);
+            if depth.is_some() && half > 1e-3 && half < std::f64::consts::FRAC_PI_2 && !exits_at_shoulder {
                 // One revolved tool (cylinder with a drill point).
                 let tip = r / half.tan();
                 let up = -dir;
diff --git a/crates/engine/src/tests.rs b/crates/engine/src/tests.rs
index f72f7d96..cae0f978 100644
--- a/crates/engine/src/tests.rs
+++ b/crates/engine/src/tests.rs
@@ -1558,3 +1558,30 @@ fn lip_after_boss() {
         }
     }
 }
+
+/// A drilled hole as deep as the plate: the drill point breaks through the bottom.
+#[test]
+fn hole_as_deep_as_the_plate() {
+    let mut s = Session::default();
+    run(&mut s, "PrimitiveBox", json!({"length": 50, "width": 25, "height": 10}));
+    let v0 = volume(&mut s);
+    run(&mut s, "FusionHoleCommand", json!({"position": [25, 12.5, 10], "diameter": 6, "depth": 10, "type": "drilled"}));
+    let v = volume(&mut s);
+    assert!(v < v0 - PI * 9.0 * 9.0 && v > v0 - PI * 9.0 * 10.0 - 1.0, "{v0} {v}");
+    // Other sizes and places, the defaults, and a tapped hole.
+    for (i, p) in [
+        json!({"position": [10, 10, 10], "diameter": 5, "depth": 10, "type": "drilled"}),
+        json!({"position": [40, 15, 10], "diameter": 5, "depth": 10}),
+        json!({"position": [12, 6, 10], "diameter": 8.5, "depth": 10}),
+        json!({"position": [30, 7, 10], "thread": "M6", "depth": 10}),
+        json!({"position": [20, 18, 10], "diameter": 4, "depth": 10, "tip_angle": 90}),
+    ]
+    .into_iter()
+    .enumerate()
+    {
+        let before = volume(&mut s);
+        let r = s.execute("FusionHoleCommand", &p);
+        assert!(r.is_ok(), "{i} {p}: {r:?}");
+        assert!(volume(&mut s) < before - 1.0, "{i} {p}");
+    }
+}