Fix modelling regressions and reconcile WIP UI work

crates/kernel/src/iges_in/tests.rs

@@ -150,7 +150,8 @@ fn a_drill_point_round_trips_through_iges() {
     let plate = box_solid(Vec3::new(-20.0, -15.0, 0.0), Vec3::new(20.0, 15.0, 10.0)).unwrap();
     let profile =
         Region2 { outer: Loop2::polygon(&[Vec2::new(0.0, 2.0), Vec2::new(4.0, 5.0), Vec2::new(4.0, 11.0), Vec2::new(0.0, 11.0)]), holes: vec![] };
-    let hole = crate::revolve(&Plane::XZ, &[profile], Vec2::ZERO, Vec2::new(0.0, 1.0), std::f64::consts::TAU).unwrap().pop().unwrap();
+    let plane = Plane { y: Vec3::Z, ..Plane::XZ }; // Positive profile heights are world +Z.
+    let hole = crate::revolve(&plane, &[profile], Vec2::ZERO, Vec2::new(0.0, 1.0), std::f64::consts::TAU).unwrap().pop().unwrap();
     let drilled = boolean(&plate, &hole, BoolOp::Cut).unwrap().unwrap();
     let v = 12000.0 - std::f64::consts::PI * 16.0 * (5.0 + 1.0);
     assert!(rel(measure(&drilled).unwrap().volume, v) < 1e-3);

crates/kernel/src/lib.rs

@@ -61,7 +61,7 @@ pub use lip::raise_band;
 pub use measure::{BodyMeasure, measure};
 pub use meshbody::{MAX_TRIANGLES, mesh_body};
 pub use offset::with_same_surface;
-pub use ops::{BoolOp, boolean, split_by_plane, transform, transform_matrix};
+pub use ops::{BoolOp, boolean, can_join_touching_faces, split_by_plane, transform, transform_matrix};
 pub use polybool::{faceted_boolean, planar_boolean};
 pub use polyhedron::{HalfSpace, convex_polyhedron, draft, offset_faces, shell};
 pub use sew::{EdgeSpec, FaceSpec, SurfSpec, sew};

crates/kernel/src/ops.rs

@@ -15,6 +15,12 @@ pub enum BoolOp {
     Intersect,
 }
 
+/// Whether a union can sew two matching planar faces without intersecting them.
+/// Callers can retain the exact touching tool instead of extending it into material.
+pub fn can_join_touching_faces(a: &Body, b: &Body) -> bool {
+    a.solid.boundaries().len() == 1 && b.solid.boundaries().len() == 1 && crate::coplanar::glue(a, b).is_some_and(|r| r.is_ok())
+}
+
 /// Shifts applied to both operands on retries. The boolean classifies some faces by casting a
 /// ray whose direction is derived from point coordinates; moving both solids (and the result
 /// back) leaves the geometry unchanged but changes those rays.
@@ -46,7 +52,10 @@ fn mismatch(a: &solvecraft_geom::Mesh, b: &solvecraft_geom::Mesh, result: &solve
     let hi = ba.max.min(bb.max);
     let all = ba.union(&bb);
     let mut boxes = vec![(all, 300usize)];
-    if lo.x < hi.x && lo.y < hi.y && lo.z < hi.z {
+    // A touching seam can overlap by round-off only. Samples there sit on the
+    // operands' boundaries, where ray parity cannot classify membership reliably.
+    let gap = all.diagonal().max(1.0) * 1e-9;
+    if hi.x - lo.x > gap && hi.y - lo.y > gap && hi.z - lo.z > gap {
         boxes.push((solvecraft_geom::Aabb3 { min: lo, max: hi }, 900));
     }
     let (ia_idx, ib_idx, ir_idx) = (a.inside_index(), b.inside_index(), result.inside_index());

crates/kernel/src/prism.rs

@@ -77,6 +77,7 @@ fn prism_of(b: &Body, d: Vec3, plane: &Plane, tol: f64) -> Option<Prism> {
     let mut hi = f64::NEG_INFINITY;
     let mut tops: Vec<&mt::Face> = Vec::new();
     let mut top_h = Vec::new();
+    let mut bottom_h = Vec::new();
     for f in b.solid.face_iter() {
         let surf = f.oriented_surface();
         if let mt::Surface::Plane(p) = &surf {
@@ -90,6 +91,7 @@ fn prism_of(b: &Body, d: Vec3, plane: &Plane, tol: f64) -> Option<Prism> {
                 continue;
             }
             if n.dot(d) < -1.0 + 1e-9 {
+                bottom_h.push(h);
                 lo = lo.min(h);
                 continue;
             }
@@ -110,7 +112,7 @@ fn prism_of(b: &Body, d: Vec3, plane: &Plane, tol: f64) -> Option<Prism> {
         }
     }
     // One height for every top (and bottom) cap.
-    if top_h.iter().any(|h| (h - hi).abs() > tol) || !(lo.is_finite() && hi > lo + tol) {
+    if top_h.iter().any(|h| (h - hi).abs() > tol) || bottom_h.iter().any(|h| (h - lo).abs() > tol) || !(lo.is_finite() && hi > lo + tol) {
         return None;
     }
     let mut regions = Vec::new();
@@ -382,6 +384,129 @@ fn boolean2d(a: &[Region2], b: &[Region2], op: BoolOp, tol: f64) -> Option<Vec<R
 }
 
 /// The boolean done on prism sections, or `None` when it doesn't apply.
+/// The pieces of a segment between the given points (those lying on it, inside it).
+fn split_seg(seg: &Seg2, pts: &[Vec2], tol: f64) -> Option<Vec<Seg2>> {
+    if !matches!(seg, Seg2::Line { .. } | Seg2::Arc { .. }) {
+        return None;
+    }
+    let mut ts: Vec<f64> = pts
+        .iter()
+        .filter_map(|p| {
+            let t = seg.closest_param(*p);
+            (t > 1e-9 && t < 1.0 - 1e-9 && seg.point_at(t).dist(*p) < tol).then_some(t)
+        })
+        .collect();
+    ts.sort_by(f64::total_cmp);
+    ts.dedup_by(|x, y| (*x - *y).abs() < 1e-9);
+    let mut out = Vec::new();
+    let mut t0 = 0.0;
+    for t1 in ts.into_iter().chain(std::iter::once(1.0)) {
+        out.push(match *seg {
+            Seg2::Line { .. } => Seg2::Line { a: seg.point_at(t0), b: seg.point_at(t1) },
+            Seg2::Arc { center, radius, start, sweep } => Seg2::Arc { center, radius, start: start + sweep * t0, sweep: sweep * (t1 - t0) },
+            _ => return None,
+        });
+        t0 = t1;
+    }
+    Some(out)
+}
+
+/// The union of two prisms along `d` stacked end to end (or overlapping) with different
+/// sections, sewn from its faces: each slab between the prisms' end levels has walls over its
+/// section's outline; each level has a face up over the section below less the one above, and
+/// a face down over the one above less the one below. Every outline is split where any other
+/// meets it, so the faces share their edges. `None` when a slab is empty or a curve isn't a
+/// line or an arc.
+fn sew_stack(plane: &Plane, d: Vec3, pa: &Prism, pb: &Prism, tol: f64) -> Option<Result<Body>> {
+    use crate::sew::{EdgeSpec, FaceSpec, SurfSpec};
+    let mut levels = vec![pa.lo, pa.hi, pb.lo, pb.hi];
+    levels.sort_by(f64::total_cmp);
+    levels.dedup_by(|x, y| (*x - *y).abs() < tol);
+    let covers = |p: &Prism, z0: f64, z1: f64| p.lo <= z0 + tol && p.hi >= z1 - tol;
+    let mut slabs: Vec<Vec<Region2>> = Vec::new();
+    for w in levels.windows(2) {
+        let (z0, z1) = (*w.first()?, *w.get(1)?);
+        let s = match (covers(pa, z0, z1), covers(pb, z0, z1)) {
+            (true, true) => boolean2d(&pa.regions, &pb.regions, BoolOp::Union, tol)?,
+            (true, false) => pa.regions.clone(),
+            (false, true) => pb.regions.clone(),
+            (false, false) => return None,
+        };
+        slabs.push(oriented(&s));
+    }
+    // Faces at each level: up where the slab below sticks out, down where the one above does.
+    let diff = |x: &[Region2], y: &[Region2]| -> Option<Vec<Region2>> {
+        match (x.is_empty(), y.is_empty()) {
+            (true, _) => Some(Vec::new()),
+            (false, true) => Some(x.to_vec()),
+            (false, false) => boolean2d(x, y, BoolOp::Cut, tol).map(|r| oriented(&r)),
+        }
+    };
+    let mut caps: Vec<(f64, bool, Vec<Region2>)> = Vec::new();
+    for (k, z) in levels.iter().enumerate() {
+        let below: &[Region2] = if k == 0 { &[] } else { slabs.get(k - 1)? };
+        let above: &[Region2] = slabs.get(k).map(Vec::as_slice).unwrap_or(&[]);
+        caps.push((*z, true, diff(below, above)?));
+        caps.push((*z, false, diff(above, below)?));
+    }
+    // Every segment end, everywhere: outlines split there.
+    let loops_of =
+        |rs: &[Region2]| -> Vec<Loop2> { rs.iter().flat_map(|r| std::iter::once(r.outer.clone()).chain(r.holes.iter().cloned())).collect() };
+    let mut pts: Vec<Vec2> = Vec::new();
+    for lp in slabs.iter().flat_map(|s| loops_of(s)).chain(caps.iter().flat_map(|c| loops_of(&c.2))) {
+        for sg in &lp.segs {
+            pts.push(sg.start());
+            pts.push(sg.end());
+        }
+    }
+    let at = |u: Vec2, z: f64| plane.to_world(u) + d * z;
+    let edge = |sg: &Seg2, z: f64| -> EdgeSpec {
+        match sg {
+            Seg2::Arc { .. } => EdgeSpec::Arc { a: at(sg.start(), z), b: at(sg.end(), z), mid: at(sg.point_at(0.5), z) },
+            _ => EdgeSpec::Line { a: at(sg.start(), z), b: at(sg.end(), z) },
+        }
+    };
+    let mut faces: Vec<FaceSpec> = Vec::new();
+    for (i, s) in slabs.iter().enumerate() {
+        let (z0, z1) = (*levels.get(i)?, *levels.get(i + 1)?);
+        for lp in loops_of(s) {
+            for sg0 in &lp.segs {
+                for sg in split_seg(sg0, &pts, tol)? {
+                    let (a, b) = (sg.start(), sg.end());
+                    let lp3 = vec![
+                        edge(&sg, z0),
+                        EdgeSpec::Line { a: at(b, z0), b: at(b, z1) },
+                        edge(&sg.reversed(), z1),
+                        EdgeSpec::Line { a: at(a, z1), b: at(a, z0) },
+                    ];
+                    let tangent = plane.dir_to_world(sg.derivative(0.5));
+                    let outward = tangent.cross(d).normalized()?;
+                    let surface = match sg {
+                        Seg2::Arc { .. } => SurfSpec::Extruded { a: at(a, z0), b: at(b, z0), mid: at(sg.point_at(0.5), z0), dir: d * (z1 - z0) },
+                        _ => SurfSpec::Plane,
+                    };
+                    faces.push(FaceSpec { loops: vec![lp3], surface, probe: Some((at(sg.point_at(0.5), (z0 + z1) / 2.0), outward)) });
+                }
+            }
+        }
+    }
+    for (z, up, rs) in &caps {
+        for r in rs {
+            let mut loops = Vec::new();
+            for lp in std::iter::once(&r.outer).chain(&r.holes) {
+                let mut segs: Vec<Seg2> = Vec::new();
+                for sg in &lp.segs {
+                    segs.extend(split_seg(sg, &pts, tol)?);
+                }
+                let segs: Vec<Seg2> = if *up { segs } else { segs.iter().rev().map(Seg2::reversed).collect() };
+                loops.push(segs.iter().map(|sg| edge(sg, *z)).collect::<Vec<_>>());
+            }
+            faces.push(FaceSpec { loops, surface: SurfSpec::Plane, probe: None });
+        }
+    }
+    Some(crate::sew::sew(&faces))
+}
+
 pub(crate) fn prism_boolean(a: &Body, b: &Body, op: BoolOp) -> Option<Result<Option<Body>>> {
     let size = a.size().max(b.size());
     let tol = (size * 1e-7).max(1e-9) * 10.0;
@@ -423,10 +548,10 @@ pub(crate) fn prism_boolean(a: &Body, b: &Body, op: BoolOp) -> Option<Result<Opt
         return Some(Ok(None));
     }
     let (lo, hi) = if stacked {
-        // Only when the sections are the same (the union adds nothing to either).
+        // Different sections (a boss hanging over a plate's edge): sewn slab by slab.
         let (u, x, y) = (area(&regions), area(&pa.regions), area(&pb.regions));
         if (u - x).abs() > tol * (1.0 + u) || (u - y).abs() > tol * (1.0 + u) {
-            return None;
+            return sew_stack(&plane, d, &pa, &pb, tol).map(|r| r.map(Some));
         }
         (pa.lo.min(pb.lo), pa.hi.max(pb.hi))
     } else {

crates/kernel/src/splitface.rs

@@ -1208,7 +1208,7 @@ mod tests {
         let m0 = measure(&c).unwrap();
         let side = c.faces(0.01).unwrap().iter().position(|f| f.plane_normal.is_none()).unwrap();
         // A horizontal line seen from the front (XZ sketch) at z = 5, swept along y.
-        let xz = Plane::XZ;
+        let xz = Plane { y: Vec3::Z, ..Plane::XZ };
         let tool = SplitTool::Curves { plane: xz, curves: vec![vec![Seg2::Line { a: Vec2::new(-20.0, 5.0), b: Vec2::new(20.0, 5.0) }]] };
         let s = split_faces(&c, &[side], &tool).unwrap();
         let m = measure(&s).unwrap();

crates/kernel/src/tests.rs

@@ -40,8 +40,8 @@ fn extrude_on_other_planes_and_offsets() {
     let b = extrude(&Plane::XZ, &[rect(10.0, 5.0)], -2.0, 3.0).unwrap().pop().unwrap();
     let m = measure(&b).unwrap();
     assert!(rel(m.volume, 250.0) < 1e-9);
-    // XZ normal is -Y: the body spans y in [-3, 2].
-    assert!((m.bbox.min.y + 3.0).abs() < 1e-6 && (m.bbox.max.y - 2.0).abs() < 1e-6, "{:?}", m.bbox);
+    // XZ normal is +Y: the body spans y in [-2, 3].
+    assert!((m.bbox.min.y + 2.0).abs() < 1e-6 && (m.bbox.max.y - 3.0).abs() < 1e-6, "{:?}", m.bbox);
 }
 
 #[test]
@@ -52,6 +52,39 @@ fn region_with_hole() {
     assert!(rel(m.volume, (1200.0 - PI * 25.0) * 10.0) < 5e-4, "{}", m.volume);
 }
 
+#[test]
+fn through_cut_preserves_a_larger_blind_pocket() {
+    let plate = box_solid(Vec3::new(-30.0, -28.0, 0.0), Vec3::new(60.0, 22.0, 8.0)).unwrap();
+    let pocket = cylinder(Vec3::ZERO, Vec3::Z, 11.0, 6.0).unwrap();
+    let through = cylinder(Vec3::new(0.0, 0.0, -1.0), Vec3::Z, 9.5, 10.0).unwrap();
+    let expected = 90.0 * 50.0 * 8.0 - PI * 11.0_f64.powi(2) * 6.0 - PI * 9.5_f64.powi(2) * 2.0;
+    for reverse in [false, true] {
+        let (first, second) = if reverse { (&through, &pocket) } else { (&pocket, &through) };
+        let cut = boolean(&plate, first, BoolOp::Cut).unwrap().unwrap();
+        let result = boolean(&cut, second, BoolOp::Cut).unwrap().unwrap();
+        let m = measure(&result).unwrap();
+        assert!(rel(m.volume, expected) < 5e-4, "reverse={reverse}: {} vs {expected}", m.volume);
+        assert_eq!(m.merged.faces, 9);
+        assert!(!result.tessellate(0.01).unwrap().contains(Vec3::new(10.0, 0.0, 3.0)));
+    }
+}
+
+#[test]
+fn join_a_cylinder_on_its_chamfered_top() {
+    for seam in [0.0, crate::build::SEAM_ANGLE] {
+        let region = Region2 { outer: Loop2::circle_from(Vec2::ZERO, 10.0, seam), holes: vec![] };
+        let base = extrude(&Plane::XY, &[region], 0.0, 20.0).unwrap().pop().unwrap();
+        let base = chamfer(&base, &[Vec3::new(10.0, 0.0, 20.0)], 2.0).unwrap();
+        let region = Region2 { outer: Loop2::circle_from(Vec2::new(0.0, -3.774758283725534e-15), 8.0, seam), holes: vec![] };
+        let plane = Plane { origin: Vec3::new(0.0, 0.0, 20.000000000000007), ..Plane::XY };
+        let tool = extrude(&plane, &[region], 0.0, 5.0).unwrap().pop().unwrap();
+        let expected = measure(&base).unwrap().volume + PI * 64.0 * 5.0;
+        let joined = boolean(&base, &tool, BoolOp::Union).unwrap().unwrap();
+        assert!(rel(measure(&joined).unwrap().volume, expected) < 5e-4);
+        assert_eq!(joined.lumps().unwrap().len(), 1);
+    }
+}
+
 #[test]
 fn box_fillet_cut_volume() {
     let b = box_solid(Vec3::ZERO, Vec3::new(40.0, 30.0, 20.0)).unwrap();
@@ -1344,7 +1377,8 @@ fn boolean_identity_survey() {
 fn partial_revolve_on_the_axis() {
     let sq =
         Region2 { outer: Loop2::polygon(&[Vec2::new(0.0, 0.0), Vec2::new(20.0, 0.0), Vec2::new(20.0, 7.5), Vec2::new(0.0, 7.5)]), holes: vec![] };
-    let pie = revolve(&Plane::XZ, &[sq], Vec2::ZERO, Vec2::Y, std::f64::consts::FRAC_PI_2).unwrap().pop().unwrap();
+    let plane = Plane { y: Vec3::Z, ..Plane::XZ }; // This fixture's rectangle is above z = 0.
+    let pie = revolve(&plane, &[sq], Vec2::ZERO, Vec2::Y, std::f64::consts::FRAC_PI_2).unwrap().pop().unwrap();
     assert!(pie.validity().is_empty(), "{:?}", pie.validity());
     let v = measure(&pie).unwrap().volume;
     assert!((v - PI * 400.0 / 4.0 * 7.5).abs() < 1e-3 * v, "{v}");