Files
OneCAD/crates/kernel/src/sew.rs
T
bherbruck 07932d0f42 feat: preserve modeling intent across sketches, assemblies, and fabrication
Persist typed sketch dimensions and bounded ordered configuration rules in format 8. Use exact occurrence paths and source identity for editing, movement, appearance, and mass. Preserve sheet material regions through cutting, folding, and exact DXF export; retain nested cavities and material islands.

Validation: cargo xtask ci passed, including 368 engine tests, 178 UI tests, 68 UI scenarios, 136 kernel tests, and the 10-crate wasm check. Actual preview workflows and legacy format-7 origin-corner reopening were inspected.
2026-10-11 01:28:01 -04:00

509 lines
20 KiB
Rust

//! Sewing a solid from face descriptions: each face is its boundary loops (lines and circular
//! arcs, counter-clockwise about the outward normal; holes clockwise) and its surface (planar,
//! revolved from a line, or extruded from an arc). Vertices and edges at the same places are
//! shared, so the faces close into one shell without booleans — for solids whose faces are
//! known exactly, such as folded sheet metal.
use std::collections::HashMap;
use mt::builder;
use solvecraft_geom::Vec3;
use truck_modeling as mt;
use crate::body::{Body, Solid, p3, v3};
use crate::{KernelError, Result, guard};
/// A boundary edge.
#[derive(Clone, Copy, Debug, PartialEq)]
pub enum EdgeSpec {
Line {
a: Vec3,
b: Vec3,
},
/// A circular arc from `a` to `b` through `mid`.
Arc {
a: Vec3,
b: Vec3,
mid: Vec3,
},
}
impl EdgeSpec {
fn ends(&self) -> (Vec3, Vec3) {
match *self {
EdgeSpec::Line { a, b } | EdgeSpec::Arc { a, b, .. } => (a, b),
}
}
}
/// A face's surface.
#[derive(Clone, Copy, Debug, PartialEq)]
pub enum SurfSpec {
/// The plane of the boundary.
Plane,
/// The surface the line `a`→`b` sweeps turning `angle` about the axis.
Revolved { a: Vec3, b: Vec3, axis_origin: Vec3, axis: Vec3, angle: f64 },
/// The surface an arc sweeps moving along `dir`.
Extruded { a: Vec3, b: Vec3, mid: Vec3, dir: Vec3 },
}
/// A face: boundary loops, surface, and a point on it with its outward normal (curved faces).
#[derive(Clone, Debug, PartialEq)]
pub struct FaceSpec {
pub loops: Vec<Vec<EdgeSpec>>,
pub surface: SurfSpec,
pub probe: Option<(Vec3, Vec3)>,
}
type Key = (i64, i64, i64);
fn key(p: Vec3) -> Key {
let q = |x: f64| (x * 1e6).round() as i64;
(q(p.x), q(p.y), q(p.z))
}
#[derive(Default)]
struct Cache {
verts: HashMap<Key, mt::Vertex>,
edges: HashMap<(Key, Key, Option<Key>, usize), mt::Edge>,
}
impl Cache {
fn vertex(&mut self, p: Vec3) -> mt::Vertex {
self.verts.entry(key(p)).or_insert_with(|| builder::vertex(p3(p))).clone()
}
fn edge(&mut self, e: &EdgeSpec, sheet: usize) -> mt::Edge {
let (a, b) = e.ends();
let mid = match e {
EdgeSpec::Arc { mid, .. } => Some(key(*mid)),
EdgeSpec::Line { .. } => None,
};
let (ka, kb) = (key(a), key(b));
if let Some(found) = self.edges.get(&(ka, kb, mid, sheet)) {
return found.clone();
}
if let Some(found) = self.edges.get(&(kb, ka, mid, sheet)) {
return found.inverse();
}
let (va, vb) = (self.vertex(a), self.vertex(b));
let made = match *e {
EdgeSpec::Line { .. } => builder::line(&va, &vb),
EdgeSpec::Arc { mid, .. } => builder::circle_arc(&va, &vb, p3(mid)),
};
self.edges.insert((ka, kb, mid, sheet), made.clone());
made
}
}
/// Sew the faces into a closed solid.
pub fn sew(faces: &[FaceSpec]) -> Result<Body> {
sew_impl(faces, false)
}
/// Separate boundary sheets at a shared geometric edge without moving it.
/// The face adjacency must still describe one connected solid boundary.
pub(crate) fn sew_touching(faces: &[FaceSpec]) -> Result<Body> {
sew_impl(faces, true)
}
type EdgeUse = (usize, usize, usize);
fn touching_sheets(faces: &[FaceSpec]) -> Result<HashMap<EdgeUse, usize>> {
type Use = (EdgeUse, Vec3, Vec3, Vec3);
let mut uses: HashMap<(Key, Key), Vec<Use>> = HashMap::new();
for (fi, face) in faces.iter().enumerate() {
let Some(outer) = face.loops.first() else { continue };
let normal = outer
.iter()
.fold(Vec3::ZERO, |n, e| {
let (a, b) = e.ends();
n + a.cross(b)
})
.normalized();
for (li, lp) in face.loops.iter().enumerate() {
for (ei, e) in lp.iter().enumerate() {
if matches!(e, EdgeSpec::Line { .. }) && matches!(face.surface, SurfSpec::Plane) {
let (a, b) = e.ends();
let (ka, kb) = (key(a), key(b));
let k = if ka < kb { (ka, kb) } else { (kb, ka) };
if let Some(n) = normal {
uses.entry(k).or_default().push(((fi, li, ei), a, b, n));
}
}
}
}
}
let mut sheets = HashMap::new();
for group in uses.values().filter(|g| g.len() > 2) {
if group.len() != 4 {
return Err(KernelError::Invalid("sew: unsupported edge contact".into()));
}
let mut paired = std::collections::HashSet::new();
for (i, (use_a, a, b, n)) in group.iter().enumerate() {
if paired.contains(&i) {
continue;
}
let t = (*b - *a).normalized().ok_or_else(|| KernelError::Invalid("sew: a degenerate contact".into()))?;
// Pair the two faces bounding each material wedge, not the empty
// wedge between them. Each pair uses the edge in opposite directions.
let j = group
.iter()
.enumerate()
.find_map(|(j, (_, c, d, m))| {
(i != j
&& !paired.contains(&j)
&& key(*a) == key(*d)
&& key(*b) == key(*c)
&& n.cross(t).dot(*m) < -1e-8
&& m.cross(-t).dot(*n) < -1e-8)
.then_some(j)
})
.ok_or_else(|| KernelError::Invalid("sew: ambiguous edge contact".into()))?;
let use_b = group.get(j).ok_or_else(|| KernelError::Invalid("sew: edge contact".into()))?.0;
let sheet = paired.len() / 2;
sheets.insert(*use_a, sheet);
sheets.insert(use_b, sheet);
paired.insert(i);
paired.insert(j);
}
}
Ok(sheets)
}
fn faces_connected(faces: &[mt::Face]) -> bool {
let mut by_edge: HashMap<mt::EdgeID, Vec<usize>> = HashMap::new();
for (i, f) in faces.iter().enumerate() {
for e in f.edge_iter() {
by_edge.entry(e.id()).or_default().push(i);
}
}
let mut seen = std::collections::HashSet::new();
let mut todo = vec![0];
while let Some(i) = todo.pop() {
if seen.insert(i)
&& let Some(f) = faces.get(i)
{
for e in f.edge_iter() {
if let Some(adjacent) = by_edge.get(&e.id()) {
todo.extend(adjacent.iter().copied().filter(|j| !seen.contains(j)));
}
}
}
}
seen.len() == faces.len()
}
/// Keep disconnected closed boundaries as distinct shells, preserving orientation.
fn closed_components(faces: Vec<mt::Face>) -> Result<Vec<mt::Shell>> {
const MAX_EDGE_USES: usize = 500_000;
const MAX_COMPONENTS: usize = 1024;
let fail = |s: &str| KernelError::Invalid(format!("sew: {s}"));
let mut by_edge: HashMap<mt::EdgeID, Vec<usize>> = HashMap::new();
let mut edge_uses = 0usize;
for (i, face) in faces.iter().enumerate() {
for edge in face.edge_iter() {
edge_uses = edge_uses.saturating_add(1);
if edge_uses > MAX_EDGE_USES {
return Err(fail("edge budget exceeded"));
}
let uses = by_edge.entry(edge.id()).or_default();
if uses.len() >= 2 {
return Err(fail("nonmanifold edge contact"));
}
uses.push(i);
}
}
if by_edge.values().any(|uses| uses.len() != 2) {
return Err(fail("the faces do not close"));
}
let mut seen = vec![false; faces.len()];
let mut vertices = HashMap::new();
let mut components = Vec::new();
for first in 0..faces.len() {
if seen.get(first).copied().unwrap_or(true) {
continue;
}
if components.len() >= MAX_COMPONENTS {
return Err(fail("component budget exceeded"));
}
let component = components.len();
let mut todo = vec![first];
if let Some(slot) = seen.get_mut(first) {
*slot = true;
}
let mut indices = Vec::new();
while let Some(i) = todo.pop() {
let face = faces.get(i).ok_or_else(|| fail("missing component face"))?;
indices.push(i);
for vertex in face.vertex_iter() {
if vertices.insert(vertex.id(), component).is_some_and(|previous| previous != component) {
return Err(fail("bodies touch only at a vertex"));
}
}
for edge in face.edge_iter() {
let adjacent = by_edge.get(&edge.id()).ok_or_else(|| fail("missing component edge"))?;
for j in adjacent {
let slot = seen.get_mut(*j).ok_or_else(|| fail("missing adjacent face"))?;
if !*slot {
*slot = true;
todo.push(*j);
}
}
}
}
indices.sort_unstable();
let component_faces =
indices.into_iter().map(|i| faces.get(i).cloned().ok_or_else(|| fail("missing component face"))).collect::<Result<Vec<_>>>()?;
components.push(component_faces.into());
}
Ok(components)
}
/// A contact's edge sheets can terminate in separate vertex fans. Give each fan
/// its own vertex at the same coordinates so the boundary remains a manifold.
fn split_vertex_fans(faces: Vec<mt::Face>) -> Result<Vec<mt::Face>> {
let mut by_vertex: HashMap<mt::VertexID, Vec<usize>> = HashMap::new();
let mut by_edge: HashMap<mt::EdgeID, Vec<usize>> = HashMap::new();
let mut vertices = HashMap::new();
for (i, f) in faces.iter().enumerate() {
for v in f.vertex_iter() {
vertices.insert(v.id(), v.clone());
by_vertex.entry(v.id()).or_default().push(i);
}
for e in f.edge_iter() {
by_edge.entry(e.id()).or_default().push(i);
}
}
let mut replacements: HashMap<(mt::VertexID, usize), mt::Vertex> = HashMap::new();
for (id, members) in &mut by_vertex {
members.sort_unstable();
members.dedup();
let mut seen = std::collections::HashSet::new();
let mut fans = Vec::new();
for start in members.iter().copied() {
if seen.contains(&start) {
continue;
}
let mut todo = vec![start];
let mut fan = Vec::new();
while let Some(i) = todo.pop() {
if !seen.insert(i) {
continue;
}
fan.push(i);
if let Some(f) = faces.get(i) {
for e in f.edge_iter().filter(|e| e.absolute_front().id() == *id || e.absolute_back().id() == *id) {
if let Some(adjacent) = by_edge.get(&e.id()) {
todo.extend(adjacent.iter().copied().filter(|j| !seen.contains(j)));
}
}
}
}
fans.push(fan);
}
if fans.len() > 1 {
let original = vertices.get(id).ok_or_else(|| KernelError::Failed("sew: missing contact vertex".into()))?;
for fan in fans {
let vertex = builder::vertex(original.point());
for i in fan {
replacements.insert((*id, i), vertex.clone());
}
}
}
}
let mut edges = HashMap::new();
for (i, f) in faces.iter().enumerate() {
for e in f.edge_iter() {
edges.entry(e.id()).or_insert_with(|| {
let (a, b) = (e.absolute_front(), e.absolute_back());
let a = replacements.get(&(a.id(), i)).unwrap_or(a);
let b = replacements.get(&(b.id(), i)).unwrap_or(b);
mt::Edge::new(a, b, e.curve())
});
}
}
faces
.into_iter()
.map(|f| {
let wires: Vec<mt::Wire> = f
.absolute_boundaries()
.iter()
.map(|w| {
w.edge_iter()
.map(|e| {
let rebuilt = edges.get(&e.id()).ok_or_else(|| KernelError::Failed("sew: missing contact edge".into()))?;
Ok(if e.front() == e.absolute_front() { rebuilt.clone() } else { rebuilt.inverse() })
})
.collect::<Result<Vec<_>>>()
.map(Into::into)
})
.collect::<Result<_>>()?;
let mut rebuilt = mt::Face::try_new(wires, f.surface()).map_err(|e| KernelError::Failed(format!("sew: contact face: {e}")))?;
if !f.orientation() {
rebuilt.invert();
}
Ok(rebuilt)
})
.collect()
}
fn sew_impl(faces: &[FaceSpec], touching: bool) -> Result<Body> {
if faces.len() < 4 || faces.len() > 200_000 {
return Err(KernelError::Invalid("a solid needs 4…200000 faces".into()));
}
let mut edge_uses = 0usize;
for f in faces {
for l in &f.loops {
edge_uses = edge_uses.saturating_add(l.len().max(1));
if edge_uses > 500_000 {
return Err(KernelError::Invalid("sew: edge budget exceeded".into()));
}
for e in l {
let (a, b) = e.ends();
if !a.is_finite() || !b.is_finite() || a.dist(b) < 1e-9 {
return Err(KernelError::Invalid("sew: a degenerate edge".into()));
}
}
}
}
guard("sew", || {
let sheets = if touching { touching_sheets(faces)? } else { HashMap::new() };
let mut cache = Cache::default();
let mut out: Vec<mt::Face> = Vec::with_capacity(faces.len());
for (fi, f) in faces.iter().enumerate() {
let wires: Vec<mt::Wire> = f
.loops
.iter()
.enumerate()
.map(|(li, l)| {
l.iter().enumerate().map(|(ei, e)| cache.edge(e, sheets.get(&(fi, li, ei)).copied().unwrap_or(0))).collect::<Vec<_>>().into()
})
.collect();
let face = match f.surface {
SurfSpec::Plane => builder::try_attach_plane(&wires).map_err(|e| KernelError::Failed(format!("sew: face {fi}: {e}")))?,
SurfSpec::Revolved { a, b, axis_origin, axis, angle } => {
let k = axis.normalized().ok_or_else(|| KernelError::Invalid("sew: axis".into()))?;
let (va, vb) = (builder::vertex(p3(a)), builder::vertex(p3(b)));
let swept: mt::Shell = builder::rsweep(&builder::line(&va, &vb), p3(axis_origin), v3(k), mt::Rad(angle));
let tmp = swept.face_iter().next().cloned().ok_or_else(|| KernelError::Failed("sew: revolved surface".into()))?;
curved(tmp.oriented_surface(), wires, f.probe, fi)?
}
SurfSpec::Extruded { a, b, mid, dir } => {
let (va, vb) = (builder::vertex(p3(a)), builder::vertex(p3(b)));
let tmp: mt::Face = builder::tsweep(&builder::circle_arc(&va, &vb, p3(mid)), v3(dir));
curved(tmp.oriented_surface(), wires, f.probe, fi)?
}
};
out.push(face);
}
if !sheets.is_empty() && !faces_connected(&out) {
return Err(KernelError::Invalid("sew: bodies touch only along an edge".into()));
}
if !sheets.is_empty() {
out = split_vertex_fans(out)?;
}
let shells = closed_components(out)?;
let solid = Solid::try_new(shells).map_err(|e| KernelError::Failed(format!("sew: the faces do not close: {e}")))?;
Body::new(solid)
})
}
/// A curved face on `surf`, turned so its normal at the probe points outward.
fn curved(mut surf: mt::Surface, wires: Vec<mt::Wire>, probe: Option<(Vec3, Vec3)>, fi: usize) -> Result<mt::Face> {
use mt::{ParametricSurface3D, SearchParameter};
if let Some((p, outward)) = probe
&& let Some((u, v)) = surf.search_parameter(p3(p), None, 100)
{
let n = surf.normal(u, v);
if Vec3::new(n.x, n.y, n.z).dot(outward) < 0.0 {
surf = mt::Invertible::inverse(&surf);
}
}
mt::Face::try_new(wires, surf).map_err(|e| KernelError::Failed(format!("sew: face {fi}: {e}")))
}
#[cfg(test)]
mod tests {
use super::*;
fn quad(a: Vec3, b: Vec3, c: Vec3, d: Vec3) -> FaceSpec {
FaceSpec {
loops: vec![vec![EdgeSpec::Line { a, b }, EdgeSpec::Line { a: b, b: c }, EdgeSpec::Line { a: c, b: d }, EdgeSpec::Line { a: d, b: a }]],
surface: SurfSpec::Plane,
probe: None,
}
}
fn box_faces(origin: Vec3, size: Vec3) -> Vec<FaceSpec> {
let p = |x: f64, y: f64, z: f64| origin + Vec3::new(x * size.x, y * size.y, z * size.z);
let (a, b, c, d) = (p(0., 0., 0.), p(1., 0., 0.), p(1., 1., 0.), p(0., 1., 0.));
let (e, f, g, h) = (p(0., 0., 1.), p(1., 0., 1.), p(1., 1., 1.), p(0., 1., 1.));
vec![quad(a, d, c, b), quad(e, f, g, h), quad(a, b, f, e), quad(b, c, g, f), quad(c, d, h, g), quad(d, a, e, h)]
}
#[test]
fn disconnected_closed_faces_keep_every_material_component() {
let mut faces = box_faces(Vec3::ZERO, Vec3::new(2.0, 3.0, 4.0));
faces.extend(box_faces(Vec3::X * 10.0, Vec3::new(2.0, 3.0, 4.0)));
for reverse in [false, true] {
if reverse {
faces.reverse();
}
let body = sew(&faces).unwrap();
assert_eq!(body.shell_count(), 2);
assert!(body.validity().is_empty());
assert!((crate::measure(&body).unwrap().volume - 48.0).abs() < 1e-9);
let lumps = body.lumps().unwrap();
assert_eq!(lumps.len(), 2);
assert!(lumps.iter().all(|b| (crate::measure(b).unwrap().volume - 24.0).abs() < 1e-9));
let mesh = body.tessellate(0.01).unwrap();
assert!(mesh.contains(Vec3::new(1.0, 1.0, 1.0)));
assert!(mesh.contains(Vec3::new(11.0, 1.0, 1.0)));
assert!(!mesh.contains(Vec3::new(5.0, 1.0, 1.0)));
let imported = crate::step_import(&crate::step_export(&[&body], "sewn pieces").unwrap()).unwrap();
assert!(imported.warnings.is_empty());
let volume: f64 = imported.bodies.iter().map(|b| crate::measure(&b.body).unwrap().volume).sum();
assert!((volume - 48.0).abs() < 1e-6);
}
}
#[test]
fn sewing_preserves_inward_cavity_orientation_and_refuses_vertex_contact() {
let outer = box_faces(Vec3::ZERO, Vec3::new(2.0, 3.0, 4.0));
let mut inner = box_faces(Vec3::new(0.5, 0.75, 1.0), Vec3::new(1.0, 1.5, 2.0));
for face in &mut inner {
for lp in &mut face.loops {
lp.reverse();
for edge in lp {
if let EdgeSpec::Line { a, b } = edge {
std::mem::swap(a, b);
}
}
}
}
let cavity = sew(&outer.iter().chain(&inner).cloned().collect::<Vec<_>>()).unwrap();
assert_eq!(cavity.shell_count(), 2);
assert_eq!(cavity.lumps().unwrap().len(), 1);
assert!((crate::measure(&cavity).unwrap().volume - 21.0).abs() < 1e-9);
assert!(!cavity.tessellate(0.01).unwrap().contains(Vec3::new(1.0, 1.5, 2.0)));
let touching = box_faces(Vec3::new(2.0, 3.0, 4.0), Vec3::new(2.0, 3.0, 4.0));
assert!(sew(&outer.iter().chain(&touching).cloned().collect::<Vec<_>>()).unwrap_err().to_string().contains("vertex"));
let mut hostile = outer.clone();
hostile[0].loops = vec![Vec::new(); 500_001];
assert!(sew(&hostile).unwrap_err().to_string().contains("budget"));
}
#[test]
fn a_sewn_box() {
let p = |x: f64, y: f64, z: f64| Vec3::new(x, y, z);
let (a, b, c, d) = (p(0., 0., 0.), p(2., 0., 0.), p(2., 3., 0.), p(0., 3., 0.));
let (e, f, g, h) = (p(0., 0., 4.), p(2., 0., 4.), p(2., 3., 4.), p(0., 3., 4.));
let faces = vec![quad(a, d, c, b), quad(e, f, g, h), quad(a, b, f, e), quad(b, c, g, f), quad(c, d, h, g), quad(d, a, e, h)];
let body = sew(&faces).unwrap();
let m = crate::measure(&body).unwrap();
assert!((m.volume - 24.0).abs() < 1e-9, "{}", m.volume);
assert_eq!(body.face_count(), 6);
assert!(sew(&faces[..5]).is_err());
}
}