Meshing: start a face's boundary walk at a point the surface search finds (#882) (#1157)

When projecting a face's boundary loop onto its surface fails from an unhinted first point, the walk is retried once from the first point an unhinted search does find; a walk that succeeds is unchanged. A fillet strip on an extended surface now meshes, so the rim cut in the reported case builds in one boolean.

crates/engine/src/tests.rs

@@ -283,6 +283,7 @@ mod loft_spacing;
 mod mirror_planes;
 mod path_scope;
 mod primitive_points;
+mod rim_cut;
 mod robustness;
 mod robustness_goldens;
 mod spiral_join;

crates/engine/src/tests/rim_cut.rs

@@ -0,0 +1,57 @@
+//! #882: a cut through the open rim of a shelled case failed once an R1 round went on the outer
+//! loop of the other end face. One strip of that round (along a sloped side edge, far from the
+//! cut) was never meshed: its boundary was projected onto its surface starting from a corner
+//! that a search without a hint misses, so the face was dropped. Every boolean with the body
+//! then failed (truck's meshes both operands to classify faces), and the exact fallback refused
+//! it for the same face. The owner's design, `battery-tpu-case.solidcraft` (format 18).
+
+use std::path::Path;
+
+use serde_json::json;
+
+use super::run;
+use crate::Session;
+
+fn open_at(feature: &str) -> Session {
+    let path = Path::new(env!("CARGO_MANIFEST_DIR")).join("src/tests/fixtures/battery-tpu-case.solidcraft");
+    let mut s = Session::default();
+    run(&mut s, "doc.open", json!({"path": path.to_string_lossy()}));
+    run(&mut s, "timeline.roll_to", json!({"feature": feature}));
+    s
+}
+
+/// The window cut through the front wall and its rim, 48 × 4 × 50 from below the rim.
+fn cut_window(s: &mut Session) -> serde_json::Value {
+    run(s, "solid.box", json!({"corner": [-24, -0.5, -1], "length": 48, "width": 4, "height": 50, "operation": "cut", "targets": ["Case"]}))
+}
+
+/// Every face of the case after the round meshes (the strip had no triangles at any tolerance).
+#[test]
+fn every_face_of_the_rounded_case_meshes() {
+    let s = open_at("Fillet2");
+    let case = s.model.state().body("Case").map(|b| b.body.clone()).unwrap();
+    let faces = case.faces(0.05).unwrap();
+    assert_eq!(faces.len(), case.face_count());
+    let unmeshed: Vec<usize> = faces.iter().filter(|f| f.area <= 0.0).map(|f| f.index).collect();
+    assert!(unmeshed.is_empty(), "faces with no mesh: {unmeshed:?}");
+}
+
+/// The cut takes the same window after the round as before it (the round is 120 mm away), in one
+/// boolean with no retry.
+#[test]
+fn rim_cut_after_the_round_on_the_other_end() {
+    let mut before = open_at("Fillet1");
+    let mut after = open_at("Fillet2");
+    let faces = |s: &Session| s.model.state().body("Case").map(|b| b.body.face_count()).unwrap();
+    let (f1, f2) = (faces(&before), faces(&after));
+    cut_window(&mut before);
+    let id = cut_window(&mut after)["feature"].as_u64().unwrap();
+    let result = after.model.result(id).unwrap();
+    assert!(result.error.is_none() && result.warning.is_none(), "{result:?}");
+    assert!(result.boolean_diagnostics.events.is_empty(), "{:?}", result.boolean_diagnostics);
+    // The window's three faces (two sides and the top), at both points of the timeline.
+    assert_eq!(faces(&before), f1 + 3);
+    assert_eq!(faces(&after), f2 + 3);
+    let case = after.model.state().body("Case").map(|b| b.body.clone()).unwrap();
+    assert_eq!(case.shell_count(), 1);
+}

vendor/README.md

@@ -59,6 +59,13 @@ Changes:
   This prevents huge arbitrary pole parameters from corrupting trimmed meshes (#796),
   while retaining genuine extrapolation for unbounded planes. Work is bounded to four
   endpoint evaluations per projected point; no search or tessellation tolerance is relaxed.
+- `tessellation/triangulation.rs`: a boundary loop is projected onto its surface point by point,
+  each searched from the one before; the first has no hint. When that walk fails, it is tried
+  once more from the first point an unhinted search finds. An unhinted search can miss a point
+  that lies on the surface, such as the corner of a fillet strip on a surface extended past it,
+  and the face was then left unmeshed, which also failed every boolean with the body (#882). A
+  walk that succeeds is kept as it was: where a loop starts decides how it is laid out across a
+  periodic surface's seam.
 - `tessellation/triangulation.rs`: the inside test of a face's boundary skips loops whose
   parameter box is clear of the point (it tested every segment of every loop, so a face with
   hundreds of holes meshed in quadratic time).

vendor/truck-meshalgo/src/tessellation/triangulation.rs

@@ -411,43 +411,60 @@ impl PolyBoundaryPiece {
     ) -> Option<Self> {
         let (up, vp) = (surface.u_period(), surface.v_period());
         let (urange, vrange) = surface.try_range_tuple();
-        let mut bdry3d: Vec<Point3> = wire
+        let bdry3d: Vec<Point3> = wire
             .flat_map(|poly_edge| {
                 let n = poly_edge.len() - 1;
                 poly_edge.into_iter().take(n)
             })
             .collect();
-        bdry3d.push(bdry3d[0]);
-        let mut previous = None;
-        let mut vec = bdry3d
-            .into_iter()
-            .flat_map(|pt| {
-                let (mut u, mut v) = match sp(surface, pt, previous) {
-                    // SolidCraft: validate exact and nearest results alike, once per
-                    // boundary point, including the bounded provisional preview.
-                    Some(hint) => sane(surface, pt, hint),
-                    None => return vec![None],
-                };
-                if let (Some(up), Some((u0, _))) = (up, previous) {
-                    u = get_mindiff(u, u0, up);
-                }
-                if let (Some(vp), Some((_, v0))) = (vp, previous) {
-                    v = get_mindiff(v, v0, vp);
-                }
-                let res = (|| {
-                    if let Some((u0, v0)) = previous {
-                        if !u0.near(&u) && surface.uder(u0, v0).so_small() {
-                            return vec![Some(Point2::new(u, v0)), Some(Point2::new(u, v))];
-                        } else if !v0.near(&v) && surface.vder(u0, v0).so_small() {
-                            return vec![Some(Point2::new(u0, v)), Some(Point2::new(u, v))];
-                        }
+        let walk = |mut bdry3d: Vec<Point3>| -> Option<Vec<Point2>> {
+            bdry3d.push(bdry3d[0]);
+            let mut previous = None;
+            bdry3d
+                .into_iter()
+                .flat_map(|pt| {
+                    let (mut u, mut v) = match sp(surface, pt, previous) {
+                        // SolidCraft: validate exact and nearest results alike, once per
+                        // boundary point, including the bounded provisional preview.
+                        Some(hint) => sane(surface, pt, hint),
+                        None => return vec![None],
+                    };
+                    if let (Some(up), Some((u0, _))) = (up, previous) {
+                        u = get_mindiff(u, u0, up);
                     }
-                    vec![Some(Point2::new(u, v))]
-                })();
-                previous = Some((u, v));
-                res
-            })
-            .collect::<Option<Vec<Point2>>>()?;
+                    if let (Some(vp), Some((_, v0))) = (vp, previous) {
+                        v = get_mindiff(v, v0, vp);
+                    }
+                    let res = (|| {
+                        if let Some((u0, v0)) = previous {
+                            if !u0.near(&u) && surface.uder(u0, v0).so_small() {
+                                return vec![Some(Point2::new(u, v0)), Some(Point2::new(u, v))];
+                            } else if !v0.near(&v) && surface.vder(u0, v0).so_small() {
+                                return vec![Some(Point2::new(u0, v)), Some(Point2::new(u, v))];
+                            }
+                        }
+                        vec![Some(Point2::new(u, v))]
+                    })();
+                    previous = Some((u, v));
+                    res
+                })
+                .collect::<Option<Vec<Point2>>>()
+        };
+        // SolidCraft: each point is searched from the one before it, but the first has no
+        // hint, and a search without one can miss a point that lies on the surface (a corner of
+        // a fillet strip on a surface extended past it, #882): the whole face was then left
+        // unmeshed. When the walk fails, it is tried once more from the first point an unhinted
+        // search finds. A walk that succeeds is kept as it is (where a loop starts decides how
+        // it is laid out across a periodic surface's seam).
+        let mut vec = match walk(bdry3d.clone()) {
+            Some(vec) => vec,
+            None => {
+                let start = bdry3d.iter().skip(1).position(|pt| sp(surface, *pt, None).is_some())? + 1;
+                let mut rotated = bdry3d;
+                rotated.rotate_left(start);
+                walk(rotated)?
+            }
+        };
         let grav = vec.iter().fold(Point2::origin(), |g, p| g + p.to_vec()) / vec.len() as f64;
         if let (Some(up), Some((u0, _))) = (up, urange) {
             let quot = f64::floor((grav.x - u0) / up);