Re-land the robustness batch on main (#6): fillets running into an earlier round go to blend_corner (any radius) instead of the same-radius undo; the lip and drilled-hole regression tests move into tests/robustness.rs with the new command ids; measuring 5000 faces is checked for its counts, its time in an ignored perf test run alone

Part of #6

Co-Authored-By: Claude Opus 5.5 <[email protected]>
Claude-Session: https://claude.ai/code/session_01RjGw4gA5ZvKrU8MQP6sBgT

crates/engine/src/lib.rs

@@ -9,9 +9,9 @@
 
 pub mod cmd;
 pub mod frames;
+pub mod fuzz;
 pub mod legacy_ids;
 pub mod licences;
-pub mod fuzz;
 pub mod params;
 pub mod recovery;
 pub mod sample;

crates/engine/src/tests/robustness.rs

@@ -1,8 +1,11 @@
 //! Cases found by the robustness runs (`solvecraft-cli fuzz`, docs/robustness.md), cut down to
 //! the steps that matter, and a fixed set of seeds that must keep running clean.
 
+use std::f64::consts::PI;
+
 use serde_json::{Value, json};
 
+use super::{run, volume};
 use crate::Session;
 use crate::fuzz;
 
@@ -180,22 +183,23 @@ fn shell_after_a_drilled_hole() {
     }
 }
 
-/// Rounding an edge that runs into an earlier round of the same radius (filleting a box's
-/// edges one at a time): the same body as picking both at once. Another radius says so.
+/// Rounding a box's edges one at a time: an edge running into an earlier round (of the same
+/// radius or another) takes off about what each round alone would (the corner where they meet
+/// is small).
 #[test]
 fn fillet_into_an_earlier_round() {
     let box_ = json!({"command": "solid.box", "params": {"length": 60, "width": 40, "height": 15}});
-    let both = script(json!([box_, {"command": "solid.fillet", "params": {"edges": [[30, 0, 15], [60, 0, 7]], "radius": 2}}]));
-    let one_by_one = script(json!([
-        box_,
-        {"command": "solid.fillet", "params": {"edges": [[30, 0, 15]], "radius": 2}},
-        {"command": "solid.fillet", "params": {"edges": [[60, 0, 7]], "radius": 2}}
-    ]));
-    let (a, b) = (total_volume(&both), total_volume(&one_by_one));
-    assert!((a - b).abs() < 1e-6 * a, "{a} vs {b}");
-    let mut s = script(json!([box_, {"command": "solid.fillet", "params": {"edges": [[30, 0, 15]], "radius": 2}}]));
-    let e = s.execute("solid.fillet", &json!({"edges": [[60, 0, 7]], "radius": 3})).unwrap_err();
-    assert!(e.to_string().contains("not supported yet: an edge running into an earlier round of another radius"), "{e}");
+    for r2 in [2.0, 3.0] {
+        let s = script(json!([
+            box_,
+            {"command": "solid.fillet", "params": {"edges": [[30, 0, 15]], "radius": 2}},
+            {"command": "solid.fillet", "params": {"edges": [[60, 0, 7]], "radius": r2}}
+        ]));
+        let lost = |r: f64, len: f64| (1.0 - PI / 4.0) * r * r * len;
+        let want = 36000.0 - lost(2.0, 60.0) - lost(r2, 15.0);
+        let v = total_volume(&s);
+        assert!((v - want).abs() < 2.0, "r2 {r2}: {v} vs {want}");
+    }
 }
 
 /// Seeds that run clean: no failure, no invalid body, no volume going the wrong way.
@@ -208,3 +212,71 @@ fn fixed_seeds_run_clean() {
 }
 
 const FIXED_SEEDS: &[u64] = &[3, 5, 11, 16, 21, 29, 33, 35];
+
+/// 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, "solid.box", json!({"length": 50, "width": 25, "height": 10}));
+    let v0 = volume(&mut s);
+    run(&mut s, "solid.hole", 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("solid.hole", &p);
+        assert!(r.is_ok(), "{i} {p}: {r:?}");
+        assert!(volume(&mut s) < before - 1.0, "{i} {p}");
+    }
+}
+
+/// An enclosure built in the usual order: shell, bosses, then the lip on the rim.
+#[test]
+fn lip_after_boss() {
+    let mut s = Session::default();
+    run(&mut s, "solid.box", json!({"length": 80, "width": 50, "height": 30}));
+    run(&mut s, "solid.shell", json!({"faces": [[40, 25, 30]], "thickness": 2}));
+    run(&mut s, "plastic.boss", json!({"position": [10, 10, 2], "diameter": 7, "height": 12, "hole_diameter": 2.5}));
+    run(&mut s, "plastic.boss", json!({"position": [70, 40, 2], "diameter": 7, "height": 12, "hole_diameter": 2.5}));
+    let v0 = volume(&mut s);
+    run(&mut s, "plastic.lip", json!({"face": [1, 25, 30], "width": 1, "height": 2}));
+    let v = volume(&mut s);
+    assert!(v > v0 + 1.0, "{v0} {v}");
+    // Bosses up to the rim, with ribs, against a wall; lips, grooves and outside rims.
+    let bosses = [
+        json!({"position": [15, 15, 2], "diameter": 8, "height": 28, "hole_diameter": 3}),
+        // Ribs out to the inner walls (15 − 4 − 9 = 2), and short of them.
+        json!({"position": [15, 15, 2], "diameter": 8, "height": 12, "ribs": 4, "rib_thickness": 1.5, "rib_length": 9}),
+        json!({"position": [15, 15, 2], "diameter": 8, "height": 12, "ribs": 4, "rib_thickness": 1.5, "rib_length": 6}),
+        json!({"position": [5.5, 25, 2], "diameter": 7, "height": 12, "hole_diameter": 2.5}),
+        json!({"position": [40, 25, 2], "diameter": 8, "height": 20, "draft": "1 deg", "fillet": 1}),
+    ];
+    let lips = [
+        json!({"face": [1, 25, 30], "width": 1, "height": 2}),
+        json!({"face": [1, 25, 30], "width": 1, "height": 2, "type": "groove"}),
+        json!({"face": [1, 25, 30], "width": 1, "height": 2, "side": "outside"}),
+    ];
+    for (i, b) in bosses.iter().enumerate() {
+        for (j, l) in lips.iter().enumerate() {
+            let mut s = Session::default();
+            run(&mut s, "solid.box", json!({"length": 80, "width": 50, "height": 30}));
+            run(&mut s, "solid.shell", json!({"faces": [[40, 25, 30]], "thickness": 2}));
+            let r = s.execute("plastic.boss", b);
+            assert!(r.is_ok(), "boss {i}: {r:?}");
+            let v0 = volume(&mut s);
+            let r = s.execute("plastic.lip", l);
+            assert!(r.is_ok(), "boss {i} lip {j}: {r:?}");
+            assert!((volume(&mut s) - v0).abs() > 1.0, "boss {i} lip {j}");
+        }
+    }
+}

crates/kernel/src/blend.rs

@@ -361,15 +361,6 @@ fn blend(body: &Body, edges: &[Vec3], r: f64, shape: Shape, what: &str) -> Resul
             let attempt = match guard(what, || blend_one(&solid, &edge, size, r, shape)) {
                 Ok(o) => Ok((o, vec![j])),
                 // A curved edge, or one between curved faces: roll a ball along its smooth chain.
-                // A straight edge running into an earlier round of the same radius: that round
-                // undone and both edges rounded together (they meet in a mitre, as when picked
-                // at once).
-                Err(e) if !curved_case(&solid, &edge) && e.to_string().contains("edge ends must be planar") && shape == Shape::Round => {
-                    unround_and_blend(&cur, &edge, r, what).map(|b| ((*b.solid).clone(), vec![j])).map_err(|e2| match &e2 {
-                        KernelError::Failed(m) if m.starts_with("not supported yet: an edge running into") => e2,
-                        _ => KernelError::Failed(format!("{e} ({e2})")),
-                    })
-                }
                 Err(e) if !curved_case(&solid, &edge) => Err(e),
                 Err(e) => match smooth_chain(&solid, &edge) {
                     Some(ids) => {
@@ -808,54 +799,6 @@ pub fn chamfer_sides(body: &Body, edges: &[Vec3], d1: f64, side: ChamferSide, fl
     Ok(cur)
 }
 
-thread_local! {
-    static UNROUNDING: std::cell::Cell<bool> = const { std::cell::Cell::new(false) };
-}
-
-/// Round `edge` of `cur` where an end runs into an earlier round of radius `r`: the round is
-/// deleted (its faces healed back to the sharp edge) and both edges rounded in one go.
-fn unround_and_blend(cur: &Body, edge: &mt::Edge, r: f64, what: &str) -> Result<Body> {
-    if UNROUNDING.with(|c| c.get()) {
-        return Err(unsupported("rounds meeting rounds"));
-    }
-    let size = cur.size();
-    let mesh = cur.tessellate((size * 1e-3).max(1e-3))?;
-    let info = cur.faces((size * 1e-3).max(1e-3))?;
-    let curved = |f: usize| info.get(f).is_some_and(|x| x.plane_normal.is_none());
-    let ends = [from_p3(edge.absolute_front().point()), from_p3(edge.absolute_back().point())];
-    let mut round: Option<(usize, Vec3)> = None;
-    for q in ends {
-        let near = mesh
-            .triangles
-            .iter()
-            .zip(&mesh.tri_face)
-            .filter(|(_, f)| curved(**f as usize))
-            .filter_map(|(t, f)| mesh.tri(t).map(|[x, y, z]| (q.dist((x + y + z) / 3.0), *f as usize, (x + y + z) / 3.0)))
-            .min_by(|a, b| a.0.total_cmp(&b.0));
-        if let Some((d, f, c)) = near
-            && d < r * 2.0
-        {
-            round = Some((f, c));
-            break;
-        }
-    }
-    let (g, on_g) = round.ok_or_else(|| unsupported("the faces at the edge ends must be planar"))?;
-    let cyl = crate::topo::cylinder_face_at(cur, on_g).ok_or_else(|| unsupported("only rounds (cylinders) at the edge ends"))?;
-    if (cyl.radius - r).abs() > 1e-4 * r.max(1.0) || cyl.internal {
-        return Err(unsupported("an edge running into an earlier round of another radius (round both with one radius, or pick them together)"));
-    }
-    let faces = crate::offset::with_same_surface(cur, &[g]);
-    let sharp = crate::delete_face::delete_faces(cur, &faces)?;
-    let mid = (ends[0] + ends[1]) * 0.5;
-    // The restored edge: nearest the middle of the round (its centroid), not its ends (where
-    // the new edge is near too).
-    let old = info.get(g).map(|x| x.centroid).unwrap_or(on_g);
-    UNROUNDING.with(|c| c.set(true));
-    let r2 = blend(&sharp, &[old, mid], r, Shape::Round, what);
-    UNROUNDING.with(|c| c.set(false));
-    r2
-}
-
 pub(crate) fn chamfer_tool(cur: &Body, p: Vec3, s: f64, k: usize) -> Result<Body> {
     chamfer_tool_sides(cur, p, s, None, k)
 }

crates/kernel/src/tests.rs

@@ -1361,8 +1361,8 @@ fn boolean_of_a_body_in_pieces() {
     assert!((v - (2000.0 - 2.0 * PI * 4.0 * 10.0)).abs() < 1.0, "{v}");
 }
 
-/// Measuring a body of 5000 faces (a modelled thread is like that) stays fast and counts
-/// right: 0.8 s here, it took 13 s (a per-face recomputation of the body's size).
+/// Measuring a body of 5000 faces (a modelled thread is like that) counts right (it took 13 s,
+/// a per-face recomputation of the body's size; now under a second).
 #[test]
 fn measure_of_a_body_with_many_faces() {
     let n = 5000;
@@ -1373,9 +1373,23 @@ fn measure_of_a_body_with_many_faces() {
         })
         .collect();
     let b = extrude(&Plane::XY, &[Region2 { outer: Loop2::polygon(&pts), holes: vec![] }], 0.0, 10.0).unwrap().pop().unwrap();
-    let t = std::time::Instant::now();
     let m = measure(&b).unwrap();
-    // (A loaded build machine runs slower; the bound is loose.)
-    assert!(t.elapsed().as_secs_f64() < 5.0, "{:?}", t.elapsed());
     assert_eq!((m.merged.faces, m.merged.edges, m.merged.vertices), (n + 2, 3 * n, 2 * n), "{:?}", m.merged);
 }
+
+/// The time it takes (run alone, the suite's other tests share the machine):
+/// `cargo test --release -p solvecraft-kernel perf_measure_5000_faces -- --ignored`.
+#[test]
+#[ignore]
+fn perf_measure_5000_faces() {
+    let pts: Vec<Vec2> = (0..5000)
+        .map(|i| {
+            let a = std::f64::consts::TAU * i as f64 / 5000.0;
+            Vec2::new(20.0 * a.cos(), 20.0 * a.sin())
+        })
+        .collect();
+    let b = extrude(&Plane::XY, &[Region2 { outer: Loop2::polygon(&pts), holes: vec![] }], 0.0, 10.0).unwrap().pop().unwrap();
+    let t = std::time::Instant::now();
+    measure(&b).unwrap();
+    assert!(t.elapsed().as_secs_f64() < 1.5, "{:?}", t.elapsed());
+}

docs/robustness.md

@@ -94,9 +94,9 @@ Found by QA on new users' first steps, each with an engine test against the anal
 - **Shell thinner than a round tangent to the open face** (1.5 mm): every face moves in
   (tangencies keep) and the opening is the open face's copy swept out through the body.
 - **Shell after a drilled hole** (its tip a cone).
-- **Filleting a box's edges one at a time**: an edge that runs into an earlier round of the
-  same radius undoes that round and rounds both together, the same body as picking both at once.
-  Another radius says what to do; Fusion's corner patch for it is still missing.
+- **Filleting a box's edges one at a time**: an edge that runs into an earlier round takes
+  that round off and rounds both together, with the corner where they meet (`blend_corner.rs`,
+  any radii).
 
 ### Speed