From 4a86ad5a7cb504e38e63bfdb7c33371081719294 Mon Sep 17 00:00:00 2001
From: Jonas Wrede <jonas.wrede@beyondit.gmbh>
Date: Tue, 13 Oct 2026 10:26:07 +0200
Subject: [PATCH] fix: extend a cut or join tool only past an end that lies on
 a target face (#545, #544) (#609)

An extrude cut or join only extends its tool past an end that lies on a target face, and by less than half the way to the next face level, so a tool can no longer cut through a thin floor beyond an end that touches no face. Un-ignores the #545 and #544 regression tests. Fixes #545.

Co-authored-by: jonaswre <jonas.wrede@beyondit.gmbh>
---
 crates/doc/src/eval.rs                        | 35 ++++++++++++++++---
 crates/engine/src/boolean_regression_tests.rs |  2 --
 2 files changed, 30 insertions(+), 7 deletions(-)

diff --git a/crates/doc/src/eval.rs b/crates/doc/src/eval.rs
index 5c7d8d42..a065ba03 100644
--- a/crates/doc/src/eval.rs
+++ b/crates/doc/src/eval.rs
@@ -1494,7 +1494,10 @@ fn grow_profile_for_coplanar(st: &ModelState, r: &Region2, op: Operation, target
 
 /// Booleans struggle with coincident faces (a cut starting on the face it cuts, a boss
 /// starting on the face it joins). Extending the tool past such an end changes nothing when the
-/// space beyond is empty (cut) or already material (join), so do exactly that.
+/// space beyond is empty (cut) or already material (join), so do exactly that. Only an end
+/// that lies on a target face parallel to it moves, and by less than half the way to the next
+/// such face level: the samples can miss material beyond the end (a thin floor between a recess
+/// above and a ring pocket below), which a longer tool would cut through.
 fn extend_for_coplanar(st: &ModelState, plane: &Plane, r: &Region2, lo: f64, hi: f64, op: Operation, targets: &[String]) -> (f64, f64) {
     if !matches!(op, Operation::Cut | Operation::Join) || st.bodies.is_empty() {
         return (lo, hi);
@@ -1509,18 +1512,40 @@ fn extend_for_coplanar(st: &ModelState, plane: &Plane, r: &Region2, lo: f64, hi:
     let samples = region_samples(r);
     let n = plane.normal();
     let inside_any = |p: Vec3| meshes.iter().any(|m| m.contains(p));
-    let ok_beyond = |h: f64, dir: f64| {
+    // Heights of the targets' faces parallel to the profile plane.
+    let tol = (size * 1e-7).max(1e-9);
+    let levels: Vec<f64> = meshes
+        .iter()
+        .flat_map(|m| {
+            m.triangles.iter().filter_map(|t| {
+                let [a, b, c] = m.tri(t)?;
+                let normal = (b - a).cross(c - a).normalized()?;
+                (normal.dot(n).abs() > 1.0 - 1e-9).then(|| (a - plane.origin).dot(n))
+            })
+        })
+        .collect();
+    // How far the end at `h` may move in `dir`: zero unless a face lies on it, then short of
+    // half the gap to the next face level beyond it.
+    let room = |h: f64, dir: f64| {
+        if !levels.iter().any(|z| (z - h).abs() < tol) {
+            return 0.0;
+        }
+        let gap = levels.iter().map(|z| (z - h) * dir).filter(|g| *g > tol).fold(f64::INFINITY, f64::min);
+        delta.min(gap * 0.5)
+    };
+    let ok_beyond = |h: f64, dir: f64, step: f64| {
         samples.iter().all(|s| {
             let base = plane.to_world(*s);
             [0.5, 1.0].iter().all(|k| {
-                let p = base + n * (h + dir * delta * k);
+                let p = base + n * (h + dir * step * k);
                 let inside = inside_any(p);
                 if op == Operation::Cut { !inside } else { inside }
             })
         })
     };
-    let lo2 = if ok_beyond(lo, -1.0) { lo - delta } else { lo };
-    let hi2 = if ok_beyond(hi, 1.0) { hi + delta } else { hi };
+    let (down, up) = (room(lo, -1.0), room(hi, 1.0));
+    let lo2 = if down > tol && ok_beyond(lo, -1.0, down) { lo - down } else { lo };
+    let hi2 = if up > tol && ok_beyond(hi, 1.0, up) { hi + up } else { hi };
     (lo2, hi2)
 }
 
diff --git a/crates/engine/src/boolean_regression_tests.rs b/crates/engine/src/boolean_regression_tests.rs
index f2f15a28..3526ed89 100644
--- a/crates/engine/src/boolean_regression_tests.rs
+++ b/crates/engine/src/boolean_regression_tests.rs
@@ -93,7 +93,6 @@ fn struts_ending_on_a_bore_wall_join_without_a_panic() {
 /// yet the cut was refused (#544). It removes π · 1² · 10 mm³ (within 5 %: the measure tessellates
 /// the small bore) and adds the bore's wall and floor to the bar's six faces.
 #[test]
-#[ignore = "fails until #544 is fixed"]
 fn blind_hole_into_a_long_d_profile_bar_stops_short_of_the_round_front() {
     let script: Value = serde_json::from_str(include_str!("../../../examples/regressions/blind_hole_in_long_d_profile.json")).unwrap();
     let steps = script.get("commands").and_then(Value::as_array).unwrap();
@@ -111,7 +110,6 @@ fn blind_hole_into_a_long_d_profile_bar_stops_short_of_the_round_front() {
 /// A ring pocket cut from below a recess leaves a 0.5 mm floor joining the outer wall to the inner
 /// block: one connected part, yet the cut left two bodies and lost volume (#545).
 #[test]
-#[ignore = "fails until #545 is fixed"]
 fn ring_cut_below_a_recess_keeps_the_part_in_one_body() {
     let s = replay(include_str!("../../../examples/regressions/ring_cut_below_recess_thin_floor.json"));
     let bodies: Vec<(String, f64)> = s.model.state().bodies.iter().map(|b| (b.name.clone(), volume(&s, &b.name))).collect();