Merge origin/main into fix/flush-pad-over-hole (keeps both round_pads_crossing_a_shallow_fall from #119 and drain_pads_flush_under_a_floor_with_a_hole, which now also checks a boss ring standing on the 1° top around the hole)

crates/kernel/src/build.rs

@@ -785,7 +785,8 @@ fn resample(lp: &Loop2, n: usize, angles: &[f64]) -> Loop2 {
     Loop2 { segs }
 }
 
-/// Ruled loft through two or more planar sections (outer loops only).
+/// Ruled loft through two or more planar sections (outer loops only). The sections and the
+/// same sections in reverse order give the same body.
 pub fn loft(sections: &[(Plane, Loop2)]) -> Result<Body> {
     if sections.len() < 2 || sections.len() > 50 {
         return Err(KernelError::Invalid("a loft needs 2…50 sections".into()));
@@ -794,10 +795,21 @@ pub fn loft(sections: &[(Plane, Loop2)]) -> Result<Body> {
     if n == 0 || n > MAX_SEGS {
         return Err(KernelError::Invalid("empty section".into()));
     }
-    // Orient every section counter-clockwise about the first section's normal, then match
-    // segment counts and starting points to the section with the most segments.
-    let n0 = sections[0].0.normal();
-    let oriented: Vec<(Plane, Loop2)> = sections
+    // A canonical order, so that reversing the sections changes nothing: the one whose
+    // first-to-last step has a positive largest component. The side faces' parameterisation
+    // follows the order, and the boolean worked on one and failed on the other (a cut whose
+    // loft touches the body along an edge: an internal panic, or "shell not oriented and
+    // closed").
+    let centre = |(p, l): &(Plane, Loop2)| p.to_world(l.centroid());
+    let (Some(first), Some(last)) = (sections.first(), sections.last()) else { return Err(KernelError::Invalid("no sections".into())) };
+    let step = centre(last) - centre(first);
+    let big = [step.x, step.y, step.z].into_iter().max_by(|a, b| a.abs().total_cmp(&b.abs())).unwrap_or(0.0);
+    let ordered: Vec<&(Plane, Loop2)> = if big < 0.0 { sections.iter().rev().collect() } else { sections.iter().collect() };
+    // Orient every section counter-clockwise about the first section's normal (`Body::new`
+    // turns the solid outward), then match segment counts and starting points to the section
+    // with the most segments.
+    let n0 = ordered.first().map(|(p, _)| p.normal()).unwrap_or(Vec3::Z);
+    let oriented: Vec<(Plane, Loop2)> = ordered
         .iter()
         .map(|(p, l)| {
             let l = if p.normal().dot(n0) >= 0.0 { l.ccw() } else { l.ccw().reversed() };

crates/kernel/src/offset.rs

@@ -2,8 +2,10 @@
 //! faces). Each face moves along its outward normal by its own distance: a plane is translated,
 //! a cylinder changes radius about its axis. Every vertex and edge goes to where its faces'
 //! moved surfaces meet; edges are lines or circular arcs. This is exact when the moved
-//! surfaces meet the way the old ones did (prismatic parts, bosses, fillets between walls);
-//! anything else is refused, so callers can fall back.
+//! surfaces meet the way the old ones did (prismatic parts, bosses, fillets between walls).
+//! A corner where more than three planes meet, whose moved planes miss a common point (a
+//! floor falling to a drain, a pyramid's apex), becomes several corners joined by short edges.
+//! Anything else is refused, so callers can fall back.
 
 use std::collections::HashMap;
 
@@ -422,6 +424,143 @@ fn span_step(ns: &[Vec3], s: &[f64]) -> Option<Vec3> {
     Some(v)
 }
 
+/// Most faces round one corner that [`split_corner`] takes on.
+const MAX_SPLIT_FACES: usize = 48;
+
+/// The corners in place of a corner where more than three planar faces meet and whose moved
+/// planes miss a common point (a hip floor's corner, a pyramid's apex): each new corner with
+/// the faces through it. Corners sharing two faces are joined by a new edge on those faces.
+/// Only corners whose edges are all convex or all concave: the faces there bound a convex
+/// region (the body's side or the outside's), and after the move its corners are the points on
+/// three moved planes inside all the others.
+fn split_corner(
+    v: &mt::Vertex,
+    at: &[usize],
+    faces: &[mt::Face],
+    efaces: &HashMap<mt::EdgeID, Vec<usize>>,
+    old: &[Surf],
+    new: &[Surf],
+    size: f64,
+) -> Option<Vec<(Vec3, Vec<usize>)>> {
+    if at.len() < 4 || at.len() > MAX_SPLIT_FACES {
+        return None;
+    }
+    let p = from_p3(v.point());
+    // (face, outward normal, old offset, moved offset).
+    let planes: Vec<(usize, Vec3, f64, f64)> = at
+        .iter()
+        .map(|i| match (old.get(*i)?, new.get(*i)?) {
+            (Surf::Plane { n, d }, Surf::Plane { d: d2, .. }) => Some((*i, *n, *d, *d2)),
+            _ => None,
+        })
+        .collect::<Option<_>>()?;
+    let normal = |fi: usize| planes.iter().find(|x| x.0 == fi).map(|x| x.1);
+    // Edge kinds round the corner: a face's loop runs counter-clockwise about its outward
+    // normal, so its inside is to the left; the edge is convex when the face beyond it falls
+    // away from there.
+    let mut sign = 0.0f64;
+    let mut pairs: Vec<(usize, usize)> = Vec::new();
+    for &(fi, na, ..) in &planes {
+        for w in faces.get(fi)?.boundaries() {
+            for e in w.edge_iter() {
+                if e.front().id() != v.id() && e.back().id() != v.id() {
+                    continue;
+                }
+                let fb = efaces.get(&e.id())?.iter().copied().find(|j| *j != fi)?;
+                pairs.push((fi, fb));
+                let dir = (from_p3(e.back().point()) - from_p3(e.front().point())).normalized()?;
+                let s = normal(fb)?.dot(na.cross(dir));
+                if s.abs() < 1e-9 {
+                    continue;
+                }
+                if sign * s < 0.0 {
+                    return None;
+                }
+                sign = s.signum();
+            }
+        }
+    }
+    if sign == 0.0 {
+        return None;
+    }
+    // Convex: the body's side, n·x ≤ d; concave: the outside's, n·x ≥ d.
+    let side = -sign;
+    let merge = size * 1e-6;
+    let mut nodes: Vec<(Vec3, Vec<usize>)> = Vec::new();
+    for (ia, a) in planes.iter().enumerate() {
+        for (ib, b) in planes.iter().enumerate().skip(ia + 1) {
+            for c in planes.iter().skip(ib + 1) {
+                let den = a.1.dot(b.1.cross(c.1));
+                if den.abs() < 1e-9 {
+                    continue;
+                }
+                let x = (b.1.cross(c.1) * a.3 + c.1.cross(a.1) * b.3 + a.1.cross(b.1) * c.3) * (1.0 / den);
+                if !x.is_finite() || x.dist(p) > size || planes.iter().any(|q| side * (q.1.dot(x) - q.3) > merge) {
+                    continue;
+                }
+                let fs = [a.0, b.0, c.0];
+                match nodes.iter_mut().find(|(q, _)| q.dist(x) < merge) {
+                    Some((_, nf)) => {
+                        for f in fs {
+                            if !nf.contains(&f) {
+                                nf.push(f);
+                            }
+                        }
+                    }
+                    None => nodes.push((x, fs.to_vec())),
+                }
+            }
+        }
+    }
+    // Every face keeps a corner here, and every edge an end.
+    if planes.iter().any(|q| !nodes.iter().any(|(_, nf)| nf.contains(&q.0)))
+        || pairs.iter().any(|(x, y)| !nodes.iter().any(|(_, nf)| nf.contains(x) && nf.contains(y)))
+    {
+        return None;
+    }
+    // Each corner where its planes meet best (least squares, for planes meeting at one point
+    // to within the merge distance).
+    for (q, nf) in nodes.iter_mut() {
+        let (ns, ss): (Vec<Vec3>, Vec<f64>) = nf.iter().filter_map(|f| planes.iter().find(|x| x.0 == *f)).map(|x| (x.1, x.3 - x.2)).unzip();
+        *q = p + span_step(&ns, &ss)?;
+    }
+    Some(nodes)
+}
+
+/// The corners of a split corner (see [`split_corner`]) on face `face`, in order from corner
+/// `from` to corner `to`, along the new edges between them.
+fn split_path(nodes: &[(Vec3, Vec<usize>)], face: usize, from: usize, to: usize) -> Option<Vec<usize>> {
+    let joined = |x: usize, y: usize| {
+        let (Some((_, a)), Some((_, b))) = (nodes.get(x), nodes.get(y)) else { return false };
+        a.contains(&face) && b.contains(&face) && a.iter().filter(|f| b.contains(f)).count() >= 2
+    };
+    // Breadth first; `prev` leads back to `from`.
+    let mut prev: Vec<Option<usize>> = vec![None; nodes.len()];
+    let mut queue = std::collections::VecDeque::from([from]);
+    let mut seen = vec![false; nodes.len()];
+    *seen.get_mut(from)? = true;
+    while let Some(x) = queue.pop_front() {
+        if x == to {
+            let mut path = vec![to];
+            let mut cur = to;
+            while let Some(p) = prev.get(cur).copied().flatten() {
+                path.push(p);
+                cur = p;
+            }
+            path.reverse();
+            return Some(path);
+        }
+        for y in 0..nodes.len() {
+            if !seen.get(y).copied().unwrap_or(true) && joined(x, y) {
+                *seen.get_mut(y)? = true;
+                *prev.get_mut(y)? = Some(x);
+                queue.push_back(y);
+            }
+        }
+    }
+    None
+}
+
 /// A line or circular arc through an edge (by samples): `None` for other curves.
 /// Maximum straight edges per face checked pairwise for crossings.
 const MAX_CROSSING_EDGES: usize = 2000;
@@ -431,7 +570,7 @@ const MAX_CROSSING_EDGES: usize = 2000;
 fn crossed_loops(
     faces: &[mt::Face],
     old: &[Surf],
-    newpos: &HashMap<mt::VertexID, Vec3>,
+    pos: &dyn Fn(&mt::Vertex, &mt::Edge) -> Option<Vec3>,
     edge_collapsed: &dyn Fn(&mt::Edge) -> bool,
     size: f64,
 ) -> Option<Vec3> {
@@ -443,32 +582,32 @@ fn crossed_loops(
         }
         let (u, w) = (n.any_perp(), n.cross(n.any_perp()));
         let flat = |p: Vec3| (p.dot(u), p.dot(w));
-        // Straight edges as (vertex ids, old ends, new ends) in the plane.
-        let mut segs: Vec<([mt::VertexID; 2], [(f64, f64); 2])> = Vec::new();
+        // Straight edges as (vertex ids, new ends in the plane, the plane's new offset).
+        let mut segs: Vec<([mt::VertexID; 2], [(f64, f64); 2], f64)> = Vec::new();
         for wire in f.absolute_boundaries() {
             let (mut area_old, mut area_new, mut straight) = (0.0, 0.0, true);
             for e in wire.edge_iter() {
                 let (v0, v1) = (e.front(), e.back());
-                let (Some(q0), Some(q1)) = (newpos.get(&v0.id()), newpos.get(&v1.id())) else { return None };
-                let (o0, o1, n0, n1) = (flat(from_p3(v0.point())), flat(from_p3(v1.point())), flat(*q0), flat(*q1));
+                let (Some(q0), Some(q1)) = (pos(v0, e), pos(v1, e)) else { return None };
+                let (o0, o1, n0, n1) = (flat(from_p3(v0.point())), flat(from_p3(v1.point())), flat(q0), flat(q1));
                 area_old += o0.0 * o1.1 - o1.0 * o0.1;
                 area_new += n0.0 * n1.1 - n1.0 * n0.1;
                 if arc_mid(e, size * 1e-6) == Some(None) {
-                    segs.push(([v0.id(), v1.id()], [n0, n1]));
+                    segs.push(([v0.id(), v1.id()], [n0, n1], n.dot(q0)));
                 } else {
                     straight = false;
                 }
             }
             if straight && area_old.abs() > eps && area_old * area_new <= 0.0 {
-                return wire.vertex_iter().next().and_then(|v| newpos.get(&v.id()).copied());
+                return wire.edge_iter().next().and_then(|e| pos(e.front(), e));
             }
         }
         if segs.len() > MAX_CROSSING_EDGES {
             continue;
         }
         let side = |a: (f64, f64), c: (f64, f64), p: (f64, f64)| (c.0 - a.0) * (p.1 - a.1) - (c.1 - a.1) * (p.0 - a.0);
-        for (i, (ia, [a0, a1])) in segs.iter().enumerate() {
-            for (ib, [b0, b1]) in segs.iter().skip(i + 1) {
+        for (i, (ia, [a0, a1], d)) in segs.iter().enumerate() {
+            for (ib, [b0, b1], _) in segs.iter().skip(i + 1) {
                 if ia.iter().any(|v| ib.contains(v)) {
                     continue;
                 }
@@ -478,8 +617,7 @@ fn crossed_loops(
                 if ((s0 > tol && s1 < -tol) || (s0 < -tol && s1 > tol)) && ((t0 > tol && t1 < -tol) || (t0 < -tol && t1 > tol)) {
                     let k = t0 / (t0 - t1);
                     let (x, y) = (a0.0 + (a1.0 - a0.0) * k, a0.1 + (a1.1 - a0.1) * k);
-                    let d = n.dot(newpos.get(&ia[0]).copied().unwrap_or_default());
-                    return Some(u * x + w * y + n * d);
+                    return Some(u * x + w * y + n * *d);
                 }
             }
         }
@@ -618,6 +756,8 @@ pub(crate) fn offset_body(b: &Body, shift: impl Fn(usize, Vec3) -> f64) -> Resul
         })
         .collect();
     let mut newpos: HashMap<mt::VertexID, Vec3> = HashMap::new();
+    // Corners whose moved faces meet at several points (see `split_corner`).
+    let mut splits: HashMap<mt::VertexID, Vec<(Vec3, Vec<usize>)>> = HashMap::new();
     for v in b.solid.vertex_iter() {
         let at = vfaces.get(&v.id()).ok_or_else(|| fail("vertex"))?;
         let p = from_p3(v.point());
@@ -672,10 +812,33 @@ pub(crate) fn offset_body(b: &Body, shift: impl Fn(usize, Vec3) -> f64) -> Resul
         });
         let q = match apex {
             Some(q) if n.iter().all(|sf| sf.dist(q).abs() < size * 1e-6) => q,
-            _ => move_point(p, &o, &s, &n, size * 1e-6).ok_or_else(|| fail("a corner whose faces don't meet the same way after the move"))?,
+            _ => match move_point(p, &o, &s, &n, size * 1e-6) {
+                Some(q) => q,
+                None => {
+                    let nodes = (fs == *at)
+                        .then(|| split_corner(&v, at, &faces, &efaces, &old, &new, size))
+                        .flatten()
+                        .ok_or_else(|| fail("a corner whose faces don't meet the same way after the move"))?;
+                    let q = nodes.first().map(|x| x.0).ok_or_else(|| fail("corner"))?;
+                    splits.insert(v.id(), nodes);
+                    q
+                }
+            },
         };
         newpos.insert(v.id(), q);
     }
+    // Which of a split corner's new corners an edge ends at.
+    let node_of = |v: mt::VertexID, e: mt::EdgeID| -> Option<usize> {
+        let fs = efaces.get(&e)?;
+        splits.get(&v)?.iter().position(|(_, nf)| fs.iter().all(|i| nf.contains(i)))
+    };
+    // Where an edge's end goes.
+    let end_pos = |v: &mt::Vertex, e: &mt::Edge| -> Option<Vec3> {
+        match splits.get(&v.id()) {
+            Some(nodes) => nodes.get(node_of(v.id(), e.id())?).map(|x| x.0),
+            None => newpos.get(&v.id()).copied(),
+        }
+    };
     // An edge turned round: faces crossed over (a wall thinner than the move), which would
     // leave the body inside out.
     let edge_collapsed = |e: &mt::Edge| efaces.get(&e.id()).is_some_and(|fs| fs.iter().any(|i| is_collapsed(*i)));
@@ -684,8 +847,8 @@ pub(crate) fn offset_body(b: &Body, shift: impl Fn(usize, Vec3) -> f64) -> Resul
             continue;
         }
         let (f0, f1) = (e.absolute_front(), e.absolute_back());
-        let (Some(q0), Some(q1)) = (newpos.get(&f0.id()), newpos.get(&f1.id())) else { continue };
-        let (old_v, new_v) = (from_p3(f1.point()) - from_p3(f0.point()), *q1 - *q0);
+        let (Some(q0), Some(q1)) = (end_pos(f0, &e), end_pos(f1, &e)) else { continue };
+        let (old_v, new_v) = (from_p3(f1.point()) - from_p3(f0.point()), q1 - q0);
         if old_v.len() > size * 1e-6 && old_v.dot(new_v) < 0.0 {
             return Err(fail("not supported yet: the move is larger than a wall or step is thick (faces would cross)"));
         }
@@ -693,7 +856,7 @@ pub(crate) fn offset_body(b: &Body, shift: impl Fn(usize, Vec3) -> f64) -> Resul
     // A plane's loops crossing after the move: a rim or ledge narrower than the move (the hole
     // in a top face sliding past its outer edge) turns part of the face inside out, though no
     // edge turns round.
-    if let Some(at) = crossed_loops(&faces, &old, &newpos, &edge_collapsed, size) {
+    if let Some(at) = crossed_loops(&faces, &old, &end_pos, &edge_collapsed, size) {
         return Err(fail(&format!(
             "not supported yet: the move is larger than a rim or ledge near [{:.1}, {:.1}, {:.1}] is wide (a face would turn inside out)",
             at.x, at.y, at.z
@@ -725,6 +888,16 @@ pub(crate) fn offset_body(b: &Body, shift: impl Fn(usize, Vec3) -> f64) -> Resul
             };
             verts.insert(v.id(), nv);
         }
+        let node_verts: HashMap<mt::VertexID, Vec<mt::Vertex>> =
+            splits.iter().map(|(id, nodes)| (*id, nodes.iter().map(|(q, _)| builder::vertex(p3(*q))).collect())).collect();
+        let vert_at = |v: &mt::Vertex, e: &mt::Edge| -> Option<&mt::Vertex> {
+            match node_verts.get(&v.id()) {
+                Some(nv) => nv.get(node_of(v.id(), e.id())?),
+                None => verts.get(&v.id()),
+            }
+        };
+        // New edges between a split corner's corners (stored from the lower index).
+        let mut links: HashMap<(mt::VertexID, usize, usize), mt::Edge> = HashMap::new();
         // Old edge → new edge, and whether it runs the other way (merged with its twin).
         let mut edges: HashMap<mt::EdgeID, (mt::Edge, bool)> = HashMap::new();
         let mut merged: HashMap<(mt::VertexID, mt::VertexID), mt::Edge> = HashMap::new();
@@ -732,7 +905,7 @@ pub(crate) fn offset_body(b: &Body, shift: impl Fn(usize, Vec3) -> f64) -> Resul
             if edges.contains_key(&e.id()) {
                 continue;
             }
-            let (Some(a), Some(c)) = (verts.get(&e.absolute_front().id()), verts.get(&e.absolute_back().id())) else { return Err(fail("edge")) };
+            let (Some(a), Some(c)) = (vert_at(e.absolute_front(), &e), vert_at(e.absolute_back(), &e)) else { return Err(fail("edge")) };
             let touches = edge_collapsed(&e);
             if a == c || from_p3(a.point()).dist(from_p3(c.point())) < size * 1e-9 {
                 if touches {
@@ -796,18 +969,37 @@ pub(crate) fn offset_body(b: &Body, shift: impl Fn(usize, Vec3) -> f64) -> Resul
             if is_collapsed(i) {
                 continue;
             }
-            let wires: Vec<mt::Wire> = f
-                .absolute_boundaries()
-                .iter()
-                .map(|w| {
-                    w.edge_iter()
-                        .filter_map(|e| {
-                            edges.get(&e.id()).map(|(ne, flip)| if (e.front() == e.absolute_front()) != *flip { ne.clone() } else { ne.inverse() })
-                        })
-                        .collect::<Vec<_>>()
-                        .into()
-                })
-                .collect();
+            let mut wires: Vec<mt::Wire> = Vec::new();
+            for w in f.absolute_boundaries() {
+                let old_edges: Vec<mt::Edge> = w.edge_iter().cloned().collect();
+                let mut wire: Vec<mt::Edge> = Vec::new();
+                for (j, e) in old_edges.iter().enumerate() {
+                    if let Some((ne, flip)) = edges.get(&e.id()) {
+                        wire.push(if (e.front() == e.absolute_front()) != *flip { ne.clone() } else { ne.inverse() });
+                    }
+                    // At a split corner, along the new edges from this edge's end to the next's.
+                    let v = e.back();
+                    let (Some(nodes), Some(next)) = (splits.get(&v.id()), old_edges.get((j + 1) % old_edges.len())) else { continue };
+                    let (Some(from), Some(to)) = (node_of(v.id(), e.id()), node_of(v.id(), next.id())) else { return Err(fail("split corner")) };
+                    let path = split_path(nodes, i, from, to).ok_or_else(|| fail("split corner"))?;
+                    for pair in path.windows(2) {
+                        let (Some(&x), Some(&y)) = (pair.first(), pair.get(1)) else { continue };
+                        let key = (v.id(), x.min(y), x.max(y));
+                        let link = match links.get(&key) {
+                            Some(l) => l.clone(),
+                            None => {
+                                let nv = node_verts.get(&v.id()).ok_or_else(|| fail("split corner"))?;
+                                let (Some(va), Some(vb)) = (nv.get(key.1), nv.get(key.2)) else { return Err(fail("split corner")) };
+                                let l = builder::line(va, vb);
+                                links.insert(key, l.clone());
+                                l
+                            }
+                        };
+                        wire.push(if x < y { link } else { link.inverse() });
+                    }
+                }
+                wires.push(wire.into());
+            }
             let (Some(o), Some(n)) = (old.get(i), new.get(i)) else { return Err(fail("face")) };
             let surface = match (o.map_to(n), *o, *n) {
                 (Some(mat), _, _) => mt::Transformed::transformed(&f.surface(), mat),

crates/kernel/src/ops.rs

@@ -266,9 +266,12 @@ fn boolean_whole(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
     let size = a.size().max(b.size());
     // The checks mesh both bodies; where they meet in a region much thinner than they are (a
     // thin part trimmed by a long one), a step from their size would facet the small faces
-    // there coarsely enough to fail the membership test on a correct result.
+    // there coarsely enough to fail the membership test on a correct result. The meshes are
+    // refined: a round side trimmed to a thin band (a short boss crossing a gently sloping
+    // floor) is otherwise spanned by triangles cutting through it, which reads as missing
+    // material.
     let tol_m = (size * 5e-4).min(meeting_size(a, b) * 2e-3).max(size * 1e-5);
-    let meshes = (a.tessellate(tol_m).ok(), b.tessellate(tol_m).ok());
+    let meshes = (a.tessellate_with(tol_m, true).ok(), b.tessellate_with(tol_m, true).ok());
     let (va, vb) = match &meshes {
         (Some(ma), Some(mb)) => (ma.measure().volume, mb.measure().volume),
         _ => (volume(a), volume(b)),
@@ -277,7 +280,7 @@ fn boolean_whole(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
     // Volume bounds, then membership against the operands (catches misclassified pieces), on
     // one mesh of the result. Returns (plausible, volume).
     let check = |r: &Body| -> (bool, f64) {
-        let Ok(mr) = r.tessellate(tol_m) else { return (false, f64::NAN) };
+        let Ok(mr) = r.tessellate_with(tol_m, true) else { return (false, f64::NAN) };
         let v = mr.measure().volume;
         let bounds = v > 0.0
             && match op {

crates/kernel/src/polybool.rs

@@ -199,16 +199,72 @@ impl Node {
     }
 }
 
-/// Polygons of a body whose faces are all planar (None otherwise).
-fn planar_polys(b: &Body) -> Option<Vec<Poly>> {
+/// Why a body's polygons can't be had: in words that finish "the {role} has …" or "the
+/// {role}'s …".
+#[derive(Debug, PartialEq)]
+enum NotPlanar {
+    /// Faces on curved surfaces, counted by kind.
+    Curved(std::collections::BTreeMap<&'static str, usize>),
+    /// Something else (a face that could not be meshed, too many polygons).
+    Other(String),
+}
+
+impl NotPlanar {
+    fn describe(&self, role: &str) -> String {
+        match self {
+            NotPlanar::Curved(kinds) => {
+                let n: usize = kinds.values().sum();
+                let list: Vec<&str> = kinds.keys().copied().collect();
+                format!("the {role} has {n} curved face{} ({})", if n == 1 { "" } else { "s" }, list.join(", "))
+            }
+            NotPlanar::Other(m) => format!("the {role}'s {m}"),
+        }
+    }
+}
+
+/// The plane of each face (from its mesh, which must be flat), or what stands in the way: the
+/// curved faces by the kind of surface they lie on.
+fn face_planes(b: &Body, faces: &[crate::FaceInfo]) -> std::result::Result<Vec<PlaneEq>, NotPlanar> {
+    use crate::FaceSurface;
+    let mut curved: std::collections::BTreeMap<&'static str, usize> = std::collections::BTreeMap::new();
+    let mut out = Vec::with_capacity(faces.len());
+    for f in faces {
+        if f.area <= 0.0 {
+            return Err(NotPlanar::Other(format!("face {} could not be meshed", f.index)));
+        }
+        match f.plane_normal {
+            Some(n) => out.push(PlaneEq { n, w: n.dot(f.centroid) }),
+            None => {
+                let kind = match crate::face_surface(b, f.index) {
+                    Some(FaceSurface::Cylinder { .. }) => "cylinder",
+                    Some(FaceSurface::Cone { .. }) => "cone",
+                    Some(FaceSurface::Sphere { .. }) => "sphere",
+                    Some(FaceSurface::Torus { .. }) => "torus",
+                    Some(FaceSurface::Plane { .. }) => return Err(NotPlanar::Other(format!("face {} is planar but its mesh is not flat", f.index))),
+                    None => "freeform",
+                };
+                *curved.entry(kind).or_insert(0) += 1;
+            }
+        }
+    }
+    if curved.is_empty() { Ok(out) } else { Err(NotPlanar::Curved(curved)) }
+}
+
+/// Polygons of a body whose faces are all planar.
+fn planar_polys(b: &Body) -> std::result::Result<Vec<Poly>, NotPlanar> {
     let tol = (b.size() * 1e-3).max(1e-3);
-    let faces = b.faces(tol).ok()?;
-    let mesh = b.tessellate(tol).ok()?;
-    let planes: Vec<PlaneEq> = faces.iter().map(|f| f.plane_normal.map(|n| PlaneEq { n, w: n.dot(f.centroid) })).collect::<Option<_>>()?;
+    let unmeshed = |e: KernelError| NotPlanar::Other(format!("faces could not be meshed ({e})"));
+    let faces = b.faces(tol).map_err(unmeshed)?;
+    let mesh = b.tessellate(tol).map_err(unmeshed)?;
+    let planes = face_planes(b, &faces)?;
+    if mesh.triangles.len() > MAX_POLYS {
+        return Err(NotPlanar::Other(format!("mesh is too detailed ({} triangles)", mesh.triangles.len())));
+    }
+    let bad_mesh = || NotPlanar::Other("mesh is inconsistent".into());
     let mut out = Vec::new();
     for (t, fi) in mesh.triangles.iter().zip(&mesh.tri_face) {
-        let [a, bb, c] = mesh.tri(t)?;
-        let plane = *planes.get(*fi as usize)?;
+        let [a, bb, c] = mesh.tri(t).ok_or_else(bad_mesh)?;
+        let plane = *planes.get(*fi as usize).ok_or_else(bad_mesh)?;
         // Snap the vertices onto the exact face plane.
         let snap = |p: Vec3| p - plane.n * (plane.n.dot(p) - plane.w);
         let mut v = vec![snap(a), snap(bb), snap(c)];
@@ -217,7 +273,7 @@ fn planar_polys(b: &Body) -> Option<Vec<Poly>> {
         }
         out.push(Poly { v, plane });
     }
-    (out.len() <= MAX_POLYS).then_some(out)
+    Ok(out)
 }
 
 /// Polygons of any body: planar faces exactly, curved ones as their triangles (within `tol`).
@@ -305,11 +361,19 @@ pub fn faceted_boolean(a: &Body, b: &Mesh, op: BoolOp, tol: f64) -> Result<Optio
 pub fn planar_boolean(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
     a.require_brep("a boolean")?;
     b.require_brep("a boolean")?;
-    let (Some(pa), Some(pb)) = (planar_polys(a), planar_polys(b)) else {
-        if let Some(r) = sliced_planar_boolean(a, b, op) {
-            return r;
+    let (pa, pb) = match (planar_polys(a), planar_polys(b)) {
+        (Ok(pa), Ok(pb)) => (pa, pb),
+        (ra, rb) => {
+            if let Some(r) = sliced_planar_boolean(a, b, op) {
+                return r;
+            }
+            let why: Vec<String> =
+                [(ra.err(), "target"), (rb.err(), "tool")].into_iter().filter_map(|(e, role)| e.map(|e| e.describe(role))).collect();
+            return Err(KernelError::Failed(format!(
+                "not supported yet: the exact fallback for where the bodies meet (faces that touch, or cross at a shallow angle) takes planar faces only, and {}",
+                why.join(" and ")
+            )));
         }
-        return Err(KernelError::Failed("not supported yet: coincident faces on curved bodies".into()));
     };
     let size = a.size().max(b.size());
     polys_boolean(pa, pb, size, op, size * 1e-9)
@@ -320,7 +384,7 @@ pub fn planar_boolean(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
 /// hole): `a` is split across the slab, the middle piece takes the exact boolean, and the
 /// pieces outside are joined back on. `None` when no such slab exists.
 fn sliced_planar_boolean(a: &Body, b: &Body, op: BoolOp) -> Option<Result<Option<Body>>> {
-    let pb = planar_polys(b)?;
+    let pb = planar_polys(b).ok()?;
     let size = a.size().max(b.size());
     let tol = (a.size() * 1e-3).max(1e-3);
     let infos = a.faces(tol).ok()?;
@@ -391,7 +455,7 @@ fn sliced_planar_boolean(a: &Body, b: &Body, op: BoolOp) -> Option<Result<Option
             outside.extend(crate::ops::half_space(&middle, &plane, !keep_positive)?);
             middle = crate::ops::half_space(&middle, &plane, keep_positive)?.ok_or_else(|| fail("nothing beside the tool"))?;
         }
-        let pm = planar_polys(&middle).ok_or_else(|| fail("the middle piece is not planar"))?;
+        let pm = planar_polys(&middle).map_err(|e| fail(&e.describe("middle piece")))?;
         let r = polys_boolean(pm, pb, size, op, size * 1e-9)?;
         if op == BoolOp::Intersect {
             return Ok(r);

crates/kernel/src/tests.rs

@@ -334,6 +334,73 @@ fn drain_pads_flush_under_a_floor_with_a_hole() {
     let v = measure(&u).unwrap().volume;
     let expect = v_floor + PI * 400.0 * 5.0;
     assert!(rel(v, expect) < 2e-5, "disc across the hole: {v} vs {expect}");
+    // A boss ring standing on the sloping top around the hole, its foot just under the top
+    // everywhere: it adds its annulus times its height above the top at the centre.
+    let foot = 10.0 + t * 30.0 - 0.2;
+    let u = boolean(&floor, &ring(foot, 14.0), BoolOp::Union).unwrap().unwrap();
+    let v = measure(&u).unwrap().volume;
+    let expect = v_floor + PI * 300.0 * (14.0 - (10.0 + t * 50.0));
+    assert!(rel(v, expect) < 2e-5, "boss ring on the slope: {v} vs {expect}");
+    assert!(u.validity().is_empty(), "{:?}", u.validity());
+}
+
+/// A trough whose floor falls 1° (or 2° toward a drain, in four faces), and short round pads
+/// and bosses crossing the fall. The B-rep results were right, but the plausibility check meshed
+/// them without refinement: on a round side trimmed to a thin band by the shallow cut, the plain
+/// mesh spans the band with triangles cutting through the cylinder, so the check saw missing
+/// material, rejected the result, and the planar fallback refused the round pad.
+#[test]
+fn round_pads_crossing_a_shallow_fall() {
+    let hs = |n: Vec3, p: Vec3| {
+        let n = n.normalized().unwrap();
+        HalfSpace { n, d: n.dot(p) }
+    };
+    let walls = |floor: &[HalfSpace]| {
+        let mut h = vec![
+            hs(Vec3::X, Vec3::new(290.0, 0.0, 0.0)),
+            hs(-Vec3::X, Vec3::new(10.0, 0.0, 0.0)),
+            hs(Vec3::Y, Vec3::new(0.0, 140.0, 0.0)),
+            hs(-Vec3::Y, Vec3::new(0.0, 10.0, 0.0)),
+            hs(Vec3::Z, Vec3::new(0.0, 0.0, 90.0)),
+        ];
+        h.extend_from_slice(floor);
+        convex_polyhedron(&h).unwrap()
+    };
+    let block = box_solid(Vec3::ZERO, Vec3::new(300.0, 150.0, 80.0)).unwrap();
+    // One fall along x at 1°: floor z = 8 + t (x − 10).
+    let t = 1f64.to_radians().tan();
+    let fall = boolean(&block, &walls(&[hs(Vec3::new(t, 0.0, -1.0), Vec3::new(10.0, 0.0, 8.0))]), BoolOp::Cut).unwrap().unwrap();
+    let v0 = measure(&fall).unwrap().volume;
+    for x in [60.0, 100.0] {
+        // A pad from z = 9 to 12 (its bottom just under the floor, its top 2–3 mm above).
+        let pad = cylinder(Vec3::new(x, 75.0, 9.0), Vec3::Z, 15.0, 3.0).unwrap();
+        let u = boolean(&fall, &pad, BoolOp::Union).unwrap().unwrap();
+        // The part of the pad above the floor: the floor under the disc is planar, so its mean
+        // height is the height at the centre (where the floor is below z = 9 everywhere).
+        let floor = |x: f64| 8.0 + t * (x - 10.0);
+        let above = if floor(x - 15.0) >= 9.0 { PI * 225.0 * (12.0 - floor(x)) } else { f64::NAN };
+        let v = measure(&u).unwrap().volume;
+        if above.is_finite() {
+            assert!(rel(v, v0 + above) < 1e-5, "pad at x {x}: {v} vs {}", v0 + above);
+        } else {
+            assert!(v > v0 && v < v0 + PI * 225.0 * 3.0, "pad at x {x}: {v}");
+        }
+    }
+    // Four faces falling 2° toward a drain point, and a pad over a valley edge and a wall.
+    let t2 = 2f64.to_radians().tan();
+    let d = Vec3::new(240.0, 110.0, 8.0);
+    let hopper = walls(&[
+        hs(Vec3::new(t2, 0.0, -1.0), d),
+        hs(Vec3::new(-t2, 0.0, -1.0), d),
+        hs(Vec3::new(0.0, t2, -1.0), d),
+        hs(Vec3::new(0.0, -t2, -1.0), d),
+    ]);
+    let trough = boolean(&block, &hopper, BoolOp::Cut).unwrap().unwrap();
+    let pad = cylinder(Vec3::new(270.0, 70.0, 8.0), Vec3::Z, 25.0, 5.0).unwrap();
+    let u = boolean(&trough, &pad, BoolOp::Union).unwrap().unwrap();
+    // Integrated over the disc (outside the wall at x = 290): about 6517 mm³ above the floor.
+    let gain = measure(&u).unwrap().volume - measure(&trough).unwrap().volume;
+    assert!((gain - 6517.0).abs() < 10.0, "{gain}");
 }
 
 #[test]
@@ -363,6 +430,38 @@ fn planar_booleans_with_coincident_faces() {
     assert!(rel(measure(&i).unwrap().volume, 250.0) < 1e-9);
 }
 
+/// The planar fallback runs after any failed B-rep boolean, not only on coincident faces; when
+/// it can't run it says which body has which curved faces (it used to blame "coincident faces
+/// on curved bodies" whatever the cause).
+#[test]
+fn planar_fallback_names_the_curved_faces() {
+    let slab = box_solid(Vec3::ZERO, Vec3::new(40.0, 30.0, 10.0)).unwrap();
+    let pad = cylinder(Vec3::new(20.0, 15.0, 5.0), Vec3::Z, 8.0, 10.0).unwrap();
+    let e = planar_boolean(&slab, &pad, BoolOp::Union).unwrap_err().to_string();
+    assert!(e.contains("not supported yet"), "{e}");
+    assert!(e.contains("the tool has 2 curved faces (cylinder)"), "{e}");
+    assert!(!e.contains("target"), "{e}");
+    assert!(!e.contains("coincident faces on curved bodies"), "{e}");
+    let ball = sphere(Vec3::new(20.0, 15.0, 10.0), 5.0).unwrap();
+    let e = planar_boolean(&ball, &pad, BoolOp::Cut).unwrap_err().to_string();
+    assert!(e.contains("the target has 6 curved faces (sphere) and the tool has 2 curved faces (cylinder)"), "{e}");
+    // All-planar bodies, a face of one at a shallow angle (1°): the fallback takes them.
+    let slope = Vec3::new(-1f64.to_radians().tan(), 0.0, 1.0).normalized().unwrap();
+    let wedge = convex_polyhedron(&[
+        HalfSpace { n: Vec3::X, d: 30.0 },
+        HalfSpace { n: -Vec3::X, d: -10.0 },
+        HalfSpace { n: Vec3::Y, d: 20.0 },
+        HalfSpace { n: -Vec3::Y, d: -10.0 },
+        HalfSpace { n: -Vec3::Z, d: -5.0 },
+        HalfSpace { n: slope, d: slope.dot(Vec3::new(10.0, 0.0, 11.0)) },
+    ])
+    .unwrap();
+    let u = planar_boolean(&slab, &wedge, BoolOp::Union).unwrap().unwrap();
+    let above = box_solid(Vec3::new(0.0, 0.0, 10.0), Vec3::new(40.0, 30.0, 20.0)).unwrap();
+    let expect = 40.0 * 30.0 * 10.0 + measure(&boolean(&wedge, &above, BoolOp::Intersect).unwrap().unwrap()).unwrap().volume;
+    assert!(rel(measure(&u).unwrap().volume, expect) < 1e-6, "{} vs {expect}", measure(&u).unwrap().volume);
+}
+
 #[test]
 fn connected_logo_join_preserves_exact_faces_at_edge_contact() {
     let mut body = box_solid(Vec3::ZERO, Vec3::new(10.0, 20.0, 10.0)).unwrap();
@@ -1510,6 +1609,49 @@ fn smooth_loft_through_three_sections() {
     assert!(v > PI * 64.0 * 30.0 && v < 576.0 * 30.0, "{v}");
 }
 
+/// A loft from the basin's whole outline (10 up) down to a drain pad in a corner (1 up), cut
+/// from a 3 mm shell: its top edges lie on the outer walls. One order of the sections failed
+/// the cut ("shell not oriented and closed", or a panic inside the intersection), the other
+/// worked; both orders now build the same body, valid and outward.
+#[test]
+fn loft_section_order_gives_the_same_body() {
+    let r = |x0: f64, y0: f64, x1: f64, y1: f64| Loop2::polygon(&[Vec2::new(x0, y0), Vec2::new(x1, y0), Vec2::new(x1, y1), Vec2::new(x0, y1)]);
+    let at = |z: f64| Plane::new(Vec3::new(0.0, 0.0, z), Vec3::X, Vec3::Y).unwrap();
+    let big = (at(10.0), r(0.0, 0.0, 100.0, 60.0));
+    let small = (at(1.0), r(80.0, 40.0, 90.0, 50.0));
+    let basin = shell(&box_solid(Vec3::ZERO, Vec3::new(100.0, 60.0, 30.0)).unwrap(), &[Vec3::new(50.0, 30.0, 30.0)], 3.0).unwrap();
+    // The material inside the loft: the floor from 1 to 3 up, the walls from 3 to 10.
+    let v0 = measure(&basin).unwrap().volume;
+    let removed = v0 - 41582.028;
+    let mut volumes = Vec::new();
+    for secs in [vec![big.clone(), small.clone()], vec![small.clone(), big.clone()]] {
+        let l = loft(&secs).unwrap();
+        let m = measure(&l).unwrap();
+        assert!(m.volume > 0.0, "{}", m.volume);
+        volumes.push(m.volume);
+        let cut = boolean(&basin, &l, BoolOp::Cut).unwrap().unwrap();
+        let v = measure(&cut).unwrap().volume;
+        assert!((v0 - v - removed).abs() < 0.01 * removed, "{v} vs {}", v0 - removed);
+        let joined = boolean(&basin, &l, BoolOp::Union).unwrap().unwrap();
+        assert!(measure(&joined).unwrap().volume > v0);
+    }
+    assert!(rel(volumes[0], volumes[1]) < 1e-12, "{volumes:?}");
+    // Reversed in z too (large below, small above, and sketched on planes facing down).
+    let down = |z: f64| Plane::new(Vec3::new(0.0, 0.0, z), Vec3::Y, Vec3::X).unwrap();
+    for secs in [
+        vec![(at(0.0), r(0.0, 0.0, 100.0, 60.0)), (at(20.0), r(40.0, 20.0, 60.0, 40.0))],
+        vec![(down(20.0), r(20.0, 40.0, 40.0, 60.0)), (at(0.0), r(0.0, 0.0, 100.0, 60.0))],
+    ] {
+        // Prismoid: h/6 · (A0 + 4 Amid + A1).
+        let want = 20.0 / 6.0 * (6000.0 + 4.0 * 60.0 * 40.0 + 400.0);
+        let back: Vec<(Plane, Loop2)> = secs.iter().rev().cloned().collect();
+        for b in [loft(&secs).unwrap(), loft(&back).unwrap()] {
+            let v = measure(&b).unwrap().volume;
+            assert!(rel(v, want) < 1e-6, "{v} vs {want}");
+        }
+    }
+}
+
 #[test]
 fn tangent_holes_pinch_alike() {
     // Holes at ±15 and ±25 touch along a line (x = ±20); ±30 overlaps ±25. The ±25 wall is cut
@@ -1684,3 +1826,104 @@ fn orientation_mesh_reuses_missing_face_check_at_matching_tolerance() {
         }
     }
 }
+
+/// A trough whose floor falls about 1° toward a central drain, the fall starting right at the
+/// trough edges: four faces meet at each bottom corner (two walls, two fall facets) and at the
+/// drain (four facets). A tab on one end makes the body non-convex. The moved planes of four
+/// faces don't meet at one point, so each such corner of the cavity becomes two corners joined
+/// by a short edge. Checked against the volume integrated by hand.
+#[test]
+fn shell_where_four_faces_meet_at_a_corner() {
+    let (w, l, ht, t) = (100.0, 60.0, 40.0, 2.0);
+    // Drain depth: the long facets fall 1°.
+    let h = 30.0 * 1f64.to_radians().tan();
+    let facet = |n: Vec3, p: Vec3| {
+        let n = n.normalized().unwrap();
+        HalfSpace { n, d: n.dot(p) }
+    };
+    let facets = [
+        facet(Vec3::new(0.0, -h, -30.0), Vec3::ZERO),
+        facet(Vec3::new(0.0, h, -30.0), Vec3::new(0.0, l, 0.0)),
+        facet(Vec3::new(-h, 0.0, -50.0), Vec3::ZERO),
+        facet(Vec3::new(h, 0.0, -50.0), Vec3::new(w, 0.0, 0.0)),
+    ];
+    let mut hs = vec![
+        HalfSpace { n: -Vec3::X, d: 0.0 },
+        HalfSpace { n: Vec3::X, d: w },
+        HalfSpace { n: -Vec3::Y, d: 0.0 },
+        HalfSpace { n: Vec3::Y, d: l },
+        HalfSpace { n: Vec3::Z, d: ht },
+    ];
+    hs.extend(facets);
+    let trough = convex_polyhedron(&hs).unwrap();
+    let pyramid = w * l * h / 3.0;
+    assert!(rel(measure(&trough).unwrap().volume, w * l * ht + pyramid) < 1e-9);
+    let tab = box_solid(Vec3::new(w, 20.0, 20.0), Vec3::new(w + 20.0, 40.0, ht)).unwrap();
+    let body = boolean(&trough, &tab, BoolOp::Union).unwrap().unwrap();
+    let s = shell(&body, &[Vec3::new(50.0, 30.0, ht)], t).unwrap();
+    // The cavity: the walls in by t, above the floor facets moved in by t (midpoint rule; the
+    // floor is linear between its creases).
+    let floor = |x: f64, y: f64| facets.iter().map(|f| (f.d - t - f.n.x * x - f.n.y * y) / f.n.z).fold(f64::NEG_INFINITY, f64::max);
+    let (nx, ny) = (960, 560);
+    let (dx, dy) = ((w - 2.0 * t) / nx as f64, (l - 2.0 * t) / ny as f64);
+    let mut cavity = 0.0;
+    for i in 0..nx {
+        for j in 0..ny {
+            cavity += (ht - floor(t + (i as f64 + 0.5) * dx, t + (j as f64 + 0.5) * dy)) * dx * dy;
+        }
+    }
+    let tab_cavity = 20.0 * (20.0 - 2.0 * t) * (20.0 - t);
+    let want = w * l * ht + pyramid + 8000.0 - cavity - tab_cavity;
+    let m = measure(&s).unwrap();
+    assert!(rel(m.volume, want) < 1e-5, "{} vs {want}", m.volume);
+}
+
+/// The same trough cut as a pocket into a slab (four faces meet at each concave corner of the
+/// pocket floor), shelled with its top open.
+#[test]
+fn shell_of_a_pocket_whose_floor_falls_to_a_drain() {
+    let (px, py, pw, pl, top, depth, t) = (20.0, 15.0, 100.0, 60.0, 50.0, 30.0, 3.0);
+    let h = 30.0 * 1f64.to_radians().tan();
+    let z0 = top - depth;
+    let facet = |n: Vec3, p: Vec3| {
+        let n = n.normalized().unwrap();
+        HalfSpace { n, d: n.dot(p) }
+    };
+    let facets = [
+        facet(Vec3::new(0.0, -h, -30.0), Vec3::new(px, py, z0)),
+        facet(Vec3::new(0.0, h, -30.0), Vec3::new(px, py + pl, z0)),
+        facet(Vec3::new(-h, 0.0, -50.0), Vec3::new(px, py, z0)),
+        facet(Vec3::new(h, 0.0, -50.0), Vec3::new(px + pw, py, z0)),
+    ];
+    let mut hs = vec![
+        HalfSpace { n: -Vec3::X, d: -px },
+        HalfSpace { n: Vec3::X, d: px + pw },
+        HalfSpace { n: -Vec3::Y, d: -py },
+        HalfSpace { n: Vec3::Y, d: py + pl },
+        HalfSpace { n: Vec3::Z, d: top + 10.0 },
+    ];
+    hs.extend(facets);
+    let pocket = convex_polyhedron(&hs).unwrap();
+    let slab = box_solid(Vec3::ZERO, Vec3::new(140.0, 90.0, top)).unwrap();
+    let basin = boolean(&slab, &pocket, BoolOp::Cut).unwrap().unwrap();
+    let pocket_vol = pw * pl * depth + pw * pl * h / 3.0;
+    assert!(rel(measure(&basin).unwrap().volume, 140.0 * 90.0 * top - pocket_vol) < 1e-9);
+    let s = shell(&basin, &[Vec3::new(5.0, 5.0, top)], t).unwrap();
+    // The cavity's columns: from t up to the top, or up to the pocket floor moved down by t
+    // inside the pocket's walls moved out by t.
+    let floor = |x: f64, y: f64| facets.iter().map(|f| (f.d + t - f.n.x * x - f.n.y * y) / f.n.z).fold(f64::NEG_INFINITY, f64::max);
+    let (nx, ny) = (1340, 840);
+    let (dx, dy) = ((140.0 - 2.0 * t) / nx as f64, (90.0 - 2.0 * t) / ny as f64);
+    let mut cavity = 0.0;
+    for i in 0..nx {
+        for j in 0..ny {
+            let (x, y) = (t + (i as f64 + 0.5) * dx, t + (j as f64 + 0.5) * dy);
+            let inside = x > px - t && x < px + pw + t && y > py - t && y < py + pl + t;
+            let roof = if inside { floor(x, y) } else { top };
+            cavity += (roof - t) * dx * dy;
+        }
+    }
+    let want = 140.0 * 90.0 * top - pocket_vol - cavity;
+    let m = measure(&s).unwrap();
+    assert!(rel(m.volume, want) < 1e-4, "{} vs {want}", m.volume);
+}