fix(kernel): revolving adjacent profiles on the axis makes no zero-area faces (#490)

Profiles revolved together merge into one region that keeps a vertex where
each shared edge met the axis. With the axis edge in several pieces the loop
skipped the builders for a profile with an edge on the axis, and the generic
sweep turned each piece into a degenerate face that booleans failed on.
Runs of collinear axis lines are merged into one first.

Fixes #487

Co-authored-by: Claude Opus 5.5 <[email protected]>

crates/kernel/src/build.rs

@@ -341,7 +341,15 @@ pub fn revolve(plane: &Plane, regions: &[Region2], axis_origin: Vec2, axis_dir:
                 _ => nl,
             }
         };
-        let given = numbered_region(r)?.map_loops(|l| reseam(snap_loop(l)));
+        // Adjacent profiles revolved together leave the axis edge split where they met: one
+        // edge again, so the builders for a profile with an edge on the axis take it (swept
+        // pieces of the axis are zero-area faces that booleans fail on).
+        let on_axis = |p: Vec2| d.cross(p - axis_origin).abs() < 1e-9;
+        let axis_run = |s: &Seg2, t: &Seg2| {
+            let (a, b, c) = (s.start(), s.end(), t.end());
+            on_axis(a) && on_axis(b) && on_axis(c) && (b - a).dot(c - b) > 0.0
+        };
+        let given = numbered_region(r)?.map_loops(|l| reseam(snap_loop(l).merged_lines(axis_run)));
         let r = &given.region();
         // A half disc on the axis revolved fully is a sphere: build it without poles. Every
         // patch is swept from the half disc's arcs.
@@ -388,7 +396,6 @@ pub fn revolve(plane: &Plane, regions: &[Region2], axis_origin: Vec2, axis_dir:
         // there, which truck only tessellates reliably with the axis through the world origin. Off
         // it, the body measured too large and booleans with it failed or removed the wrong side.
         // Build such a profile there and move it into place, as `revolve_touching_axis` does.
-        let on_axis = |p: Vec2| d.cross(p - axis_origin).abs() < 1e-9;
         let axis_edges = r.outer.segs.iter().filter(|s| matches!(**s, Seg2::Line { a, b } if on_axis(a) && on_axis(b))).count();
         let shift = if axis_edges > 0 { o } else { Vec3::ZERO };
         let (profile, f) = if shift.len() > 0.0 {

crates/kernel/src/numbered.rs

@@ -125,6 +125,35 @@ impl NumberedLoop {
         out
     }
 
+    /// Each run of lines that `joins` says continue one another as a single line, over what
+    /// they all ran over. (Adjacent profiles merged into one region keep a vertex where each
+    /// shared edge met the outline.)
+    pub(crate) fn merged_lines(&self, joins: impl Fn(&Seg2, &Seg2) -> bool) -> NumberedLoop {
+        let n = self.lp.segs.len();
+        let join = |i: usize, j: usize| match (self.lp.segs.get(i), self.lp.segs.get(j)) {
+            (Some(s @ Seg2::Line { .. }), Some(t @ Seg2::Line { .. })) => joins(s, t),
+            _ => false,
+        };
+        // Start where a run starts (a loop of nothing but one run stays as it is).
+        let Some(k) = (0..n).find(|&i| !join((i + n - 1) % n, i)) else { return self.clone() };
+        let mut out = NumberedLoop { lp: Loop2 { segs: Vec::new() }, from: Vec::new() };
+        for j in 0..n {
+            let i = (k + j) % n;
+            let (Some(s), from) = (self.lp.segs.get(i).copied(), self.numbers(i)) else { continue };
+            if j > 0
+                && join((i + n - 1) % n, i)
+                && let (Some(Seg2::Line { b, .. }), Some(prev)) = (out.lp.segs.last_mut(), out.from.last_mut())
+            {
+                *b = s.end();
+                *prev = union([prev.as_slice(), from]);
+                continue;
+            }
+            out.lp.segs.push(s);
+            out.from.push(from.to_vec());
+        }
+        out
+    }
+
     /// Split segment `k` in half, both halves over what it ran over.
     fn split_half(&mut self, k: usize) {
         if k >= self.lp.segs.len() || k >= self.from.len() {

crates/kernel/src/tests.rs

@@ -125,6 +125,32 @@ fn revolve_washer_and_sphere() {
     assert!(rel(ms.volume, 4.0 / 3.0 * PI * 1000.0) < 1e-3, "{}", ms.volume);
 }
 
+#[test]
+fn revolve_adjacent_profiles_on_the_axis() {
+    // Two rectangles on the axis, revolved together: their merged outline keeps a vertex
+    // where the shared edge met the axis. The swept axis pieces used to be zero-area faces,
+    // and cutting the body's flat end out of another failed.
+    let r = Region2 {
+        outer: Loop2::polygon(&[
+            Vec2::new(0.0, 0.0),
+            Vec2::new(30.0, 0.0),
+            Vec2::new(60.0, 0.0),
+            Vec2::new(60.0, 20.0),
+            Vec2::new(30.0, 20.0),
+            Vec2::new(0.0, 20.0),
+        ]),
+        holes: vec![],
+    };
+    let b = revolve(&Plane::XZ, &[r], Vec2::ZERO, Vec2::X, 2.0 * PI).unwrap().pop().unwrap();
+    assert!(rel(measure(&b).unwrap().volume, PI * 400.0 * 60.0) < 5e-4);
+    let faces = b.faces(1e-3).unwrap();
+    assert!(faces.iter().all(|f| f.area > 1e-6), "{:?}", faces.iter().map(|f| f.area).collect::<Vec<_>>());
+    let disc = cylinder(Vec3::new(-1.0, 0.0, 0.0), Vec3::X, 40.0, 3.0).unwrap();
+    let cut = boolean(&disc, &b, BoolOp::Cut).unwrap().unwrap();
+    let want = PI * 1600.0 * 3.0 - PI * 400.0 * 2.0;
+    assert!(rel(measure(&cut).unwrap().volume, want) < 1e-3, "{} vs {want}", measure(&cut).unwrap().volume);
+}
+
 #[test]
 fn chamfer_and_step() {
     let b = box_solid(Vec3::ZERO, Vec3::new(20.0, 20.0, 20.0)).unwrap();