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solidcraft-upstream/crates/kernel/src/blend.rs
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//! Edge fillets and chamfers as a local B-rep operation.
//!
//! Supported locally: a straight edge between two planar faces whose two end vertices each
//! touch exactly one more planar face. Fillets require perpendicular end faces; chamfers
//! intersect their offset rails with the end planes, including sloped walls. The end faces get an arc
//! (fillet) or a line (chamfer) at the corner, and a cylindrical (or planar) face is inserted.
//! The result is exact. Edges meeting at an already blended corner, curved edges and other
//! configurations are reported as not supported yet.
use std::collections::HashMap;
use solvecraft_geom::Vec3;
use truck_modeling::{self as mt, builder};
use crate::body::{Body, Solid, from_p3, p3, v3};
use crate::{KernelError, Result, guard};
#[derive(Clone, Copy, PartialEq)]
enum Shape {
Round,
Flat,
}
pub(crate) fn unsupported(msg: &str) -> KernelError {
KernelError::Failed(format!("not supported yet: {msg}"))
}
pub(crate) fn vtx(v: &mt::Vertex) -> Vec3 {
from_p3(v.point())
}
/// Outward unit normal of a planar face (from its oriented surface), if planar.
pub(crate) fn plane_normal(f: &mt::Face) -> Option<Vec3> {
match f.oriented_surface() {
mt::Surface::Plane(p) => {
let n = p.normal();
Vec3::new(n.x, n.y, n.z).normalized()
}
_ => None,
}
}
/// Replace edges in a face's oriented boundary (by id, keeping orientation), and insert extra
/// edges where consecutive edges no longer connect.
pub(crate) fn rebuild_face(f: &mt::Face, subst: &HashMap<mt::EdgeID, mt::Edge>, connectors: &[mt::Edge]) -> Result<mt::Face> {
let mut wires = Vec::new();
for w in f.absolute_boundaries() {
let mut edges: Vec<mt::Edge> = Vec::new();
for e in w.edge_iter() {
let ne = match subst.get(&e.id()) {
Some(n) => {
// `n` was built in the orientation of the stored edge; match this use.
let stored_forward = e.front() == e.absolute_front();
if stored_forward { n.clone() } else { n.inverse() }
}
None => e.clone(),
};
edges.push(ne);
}
// Close gaps with connector edges.
let n = edges.len();
let mut out: Vec<mt::Edge> = Vec::new();
for i in 0..n {
let (Some(cur), Some(next)) = (edges.get(i), edges.get((i + 1) % n)) else { continue };
out.push(cur.clone());
if cur.back() != next.front() {
let c = connectors
.iter()
.find_map(|c| {
if c.front() == cur.back() && c.back() == next.front() {
Some(c.clone())
} else if c.back() == cur.back() && c.front() == next.front() {
Some(c.inverse())
} else {
None
}
})
.ok_or_else(|| KernelError::Failed("blend: could not close a face boundary".into()))?;
out.push(c);
}
}
wires.push(mt::Wire::from(out));
}
crate::heal::absolute_face(f, wires).ok_or_else(|| KernelError::Failed("blend: a face could not be rebuilt".into()))
}
fn blend_one(solid: &Solid, edge: &mt::Edge, size: f64, r: f64, shape: Shape) -> Result<Solid> {
if !matches!(edge.curve(), mt::Curve::Line(_)) {
return Err(unsupported("only straight edges can be blended"));
}
let shells = solid.boundaries();
let (si, shell) = shells
.iter()
.enumerate()
.find(|(_, sh)| sh.edge_iter().any(|e| e.id() == edge.id()))
.ok_or_else(|| KernelError::Failed("edge not found".into()))?;
let faces: Vec<&mt::Face> = shell.face_iter().collect();
let on_edge: Vec<usize> = (0..faces.len()).filter(|i| faces.get(*i).is_some_and(|f| f.edge_iter().any(|e| e.id() == edge.id()))).collect();
let [i1, i2] = on_edge[..] else { return Err(unsupported("the edge is not between two faces")) };
let (Some(f1), Some(f2)) = (faces.get(i1), faces.get(i2)) else { return Err(KernelError::Failed("faces".into())) };
let (Some(n1), Some(n2)) = (plane_normal(f1), plane_normal(f2)) else { return Err(unsupported("both faces next to the edge must be planar")) };
let (v0, v1) = (edge.absolute_front().clone(), edge.absolute_back().clone());
let (p0, p1) = (vtx(&v0), vtx(&v1));
let d = (p1 - p0).normalized().ok_or_else(|| KernelError::Failed("zero-length edge".into()))?;
// In-face directions perpendicular to the edge, into each face: a face's boundary runs
// counter-clockwise about its outward normal, so its interior is to the left.
let into = |f: &mt::Face, n: Vec3| -> Option<Vec3> {
let e = f.boundary_iters().into_iter().flatten().find(|e| e.id() == edge.id())?;
let dir = (vtx(e.back()) - vtx(e.front())).normalized()?;
n.cross(dir).normalized()
};
let (Some(t1), Some(t2)) = (into(f1, n1), into(f2, n2)) else { return Err(KernelError::Failed("blend: edge direction".into())) };
// Convex edge: each face's outward normal points away from the other face; concave: toward.
let cos_phi = t1.dot(t2).clamp(-1.0, 1.0);
let phi = cos_phi.acos();
let convex = n1.dot(t2) < -1e-9 && n2.dot(t1) < -1e-9;
let concave = n1.dot(t2) > 1e-9 && n2.dot(t1) > 1e-9;
if !(phi > 1e-3 && phi < std::f64::consts::PI - 1e-3) || !(convex || concave) {
return Err(unsupported("the faces at the edge are tangent or the edge is ambiguous"));
}
// The blend's centre line is inside the material for a convex edge, outside for a concave one.
let side = if convex { -1.0 } else { 1.0 };
blend_geometry(solid, si, &faces, (i1, i2), edge, (v0, v1), (p0, p1, d), (n1, t1, t2, phi, side), size, r, shape)
}
/// Distance along each face from the edge to the blend boundary.
fn setback(r: f64, phi: f64, shape: Shape) -> f64 {
match shape {
Shape::Round => r / (phi / 2.0).tan(),
Shape::Flat => r,
}
}
/// An extended corner edge must stay in the trimmed side face, not just its infinite
/// supporting plane. Reject crossings and contact with any boundary after the old corner,
/// including holes. Curved boundaries are sampled more finely than the clearance tolerance.
pub(crate) fn extension_fits(face: &mt::Face, p: Vec3, q: Vec3, tol: f64) -> bool {
use mt::{BoundedCurve, ParameterDivision1D};
// truck requires a curve sampling tolerance of at least 1e-6. Keep the
// boundary clearance four times larger than the chord approximation error.
let tol = tol.max(4e-6);
let (Some(x), Some(n)) = ((q - p).normalized(), plane_normal(face)) else { return false };
let y = n.cross(x);
let len = p.dist(q);
if !len.is_finite() || len <= tol {
return false;
}
let mut inside = false;
for edge in face.edge_iter() {
let points = if matches!(edge.curve(), mt::Curve::Line(_)) {
vec![edge.front().point(), edge.back().point()]
} else {
let curve = edge.curve();
curve.parameter_division(curve.range_tuple(), tol * 0.25).1
};
if points.len() < 2 || points.len() > 100_000 {
return false;
}
for pair in points.windows(2) {
let [a, b] = pair else { return false };
let a = from_p3(*a) - p;
let b = from_p3(*b) - p;
let (ax, ay, bx, by) = (a.dot(x), a.dot(y), b.dot(x), b.dot(y));
if ![ax, ay, bx, by].iter().all(|v| v.is_finite()) {
return false;
}
// Contact/overlap with the extension, except its original endpoint.
if (ay.abs() <= tol && by.abs() <= tol && ax.max(bx) > tol && ax.min(bx) <= len + tol)
|| [(ax, ay), (bx, by)].iter().any(|(u, v)| *u > tol && *u <= len + tol && v.abs() <= tol)
{
return false;
}
if (ay > 0.0) != (by > 0.0) {
let hit = ax - ay * (bx - ax) / (by - ay);
if hit > tol && hit <= len + tol {
return false;
}
// Even-odd containment of q over all loops (outer boundary and holes).
if hit > len {
inside = !inside;
}
}
}
}
inside
}
#[allow(clippy::too_many_arguments)]
fn blend_geometry(
solid: &Solid,
si: usize,
faces: &[&mt::Face],
(i1, i2): (usize, usize),
edge: &mt::Edge,
(v0, v1): (mt::Vertex, mt::Vertex),
(p0, p1, d): (Vec3, Vec3, Vec3),
(n1, t1, t2, phi, side): (Vec3, Vec3, Vec3, f64, f64),
size: f64,
r: f64,
shape: Shape,
) -> Result<Solid> {
let s = setback(r, phi, shape);
let tol = (size * 1e-7).max(1e-9);
// End faces and the side edges at each end.
struct End {
v: mt::Vertex,
g: usize,
e1: mt::Edge,
e2: mt::Edge,
a: Vec3,
b: Vec3,
}
let mut ends: Vec<End> = Vec::new();
for (v, p) in [(&v0, p0), (&v1, p1)] {
let at_v: Vec<usize> = (0..faces.len()).filter(|i| faces.get(*i).is_some_and(|f| f.vertex_iter().any(|x| &x == v))).collect();
let others: Vec<usize> = at_v.iter().copied().filter(|i| *i != i1 && *i != i2).collect();
let [g] = others[..] else { return Err(unsupported("each end of the edge must touch exactly one more face")) };
let gf = faces.get(g).ok_or_else(|| KernelError::Failed("face".into()))?;
let ng = plane_normal(gf).ok_or_else(|| unsupported("the faces at the edge ends must be planar"))?;
if shape == Shape::Round && ng.dot(d).abs() < 1.0 - 1e-9 {
return Err(unsupported("the faces at the edge ends must be perpendicular to the edge"));
}
if ng.dot(d).abs() < 1e-9 {
return Err(unsupported("an end face parallel to the edge"));
}
// Each rail is parallel to the original edge and set back by s in its side
// face. Slide its endpoint along d until it lies on the actual end plane.
let endpoint = |t: Vec3| {
let q = p + t * s;
if shape == Shape::Flat { q - d * (ng.dot(t) * s / ng.dot(d)) } else { q }
};
let (a, b) = (endpoint(t1), endpoint(t2));
// Edges at v shared by g with f1 and with f2.
let shared = |fi: usize| -> Result<mt::Edge> {
let f = faces.get(fi).ok_or_else(|| KernelError::Failed("face".into()))?;
f.edge_iter()
.find(|e| e.id() != edge.id() && (e.front() == v || e.back() == v) && gf.edge_iter().any(|x| x.id() == e.id()))
.ok_or_else(|| unsupported("unexpected corner topology"))
};
let (e1, e2) = (shared(i1)?, shared(i2)?);
for (e, q, t, fi) in [(&e1, a, t1, i1), (&e2, b, t2, i2)] {
if !matches!(e.curve(), mt::Curve::Line(_)) {
return Err(unsupported("the edges at the corners must be straight"));
}
let other = if e.front() == v { vtx(e.back()) } else { vtx(e.front()) };
let delta = other - p;
if shape == Shape::Round {
// Fillets retain the square-end check: the original corner edge
// must run in the setback direction and have enough length left.
let along = delta.dot(t);
if (delta - t * along).len() > tol * 100.0 + 1e-7 || along <= s + tol {
return Err(unsupported("the blend is larger than the neighbouring faces"));
}
continue;
}
let len = delta.len();
let dir = delta.normalized().ok_or_else(|| unsupported("zero-length corner edge"))?;
let along = (q - p).dot(dir);
// An inner rim extends the neighbouring rim edge away from its other
// vertex. This is valid only within the trimmed side face.
if (q - p - dir * along).len() > tol * 100.0 + 1e-7
|| along >= len - tol
|| (along < 0.0 && !faces.get(fi).is_some_and(|f| extension_fits(f, p, q, tol)))
{
return Err(unsupported("the blend is larger than the neighbouring faces"));
}
}
ends.push(End { v: v.clone(), g, e1, e2, a, b });
}
let [end0, end1] = &ends[..] else { return Err(KernelError::Failed("ends".into())) };
if end0.g == end1.g {
return Err(unsupported("both ends touch the same face"));
}
if (end1.a - end0.a).dot(d) <= tol || (end1.b - end0.b).dot(d) <= tol {
return Err(unsupported("the blend is larger than the neighbouring faces"));
}
let a0 = builder::vertex(p3(end0.a));
let b0 = builder::vertex(p3(end0.b));
let a1 = builder::vertex(p3(end1.a));
let b1 = builder::vertex(p3(end1.b));
// Corner curves on the end faces (A → B) and the blend surface. The arc centre is r from
// both faces (inside the material for a convex edge, outside for a concave one); the arc's
// middle is the point nearest the old edge.
let centre = |p: Vec3| p + t1 * s + n1 * (r * side);
let arc_mid = |p: Vec3| {
let c = centre(p);
c + (p - c).normalized().unwrap_or(-n1) * r
};
let corner = |a: &mt::Vertex, b: &mt::Vertex, p: Vec3| -> mt::Edge {
match shape {
Shape::Round => builder::circle_arc(a, b, p3(arc_mid(p))),
Shape::Flat => builder::line(a, b),
}
};
let c0 = corner(&a0, &b0, p0);
let c1 = corner(&a1, &b1, p1);
let la = builder::line(&a0, &a1);
let lb = builder::line(&b0, &b1);
// Substitutions: side edges at the ends now stop at A/B; the blended edge moves to A or B.
let mut subst: HashMap<mt::EdgeID, mt::Edge> = HashMap::new();
for (end, a, b) in [(end0, &a0, &b0), (end1, &a1, &b1)] {
for (e, nv) in [(&end.e1, a), (&end.e2, b)] {
let (f, bk) = (e.absolute_front(), e.absolute_back());
let ne = if f == &end.v { builder::line(nv, bk) } else { builder::line(f, nv) };
subst.insert(e.id(), ne);
}
}
let mut new_faces: Vec<mt::Face> = Vec::with_capacity(faces.len() + 1);
for (i, f) in faces.iter().enumerate() {
let nf = if i == i1 {
let mut m = subst.clone();
m.insert(edge.id(), la.clone());
rebuild_face(f, &m, &[])?
} else if i == i2 {
let mut m = subst.clone();
m.insert(edge.id(), lb.clone());
rebuild_face(f, &m, &[])?
} else if i == end0.g {
rebuild_face(f, &subst, std::slice::from_ref(&c0))?
} else if i == end1.g {
rebuild_face(f, &subst, std::slice::from_ref(&c1))?
} else {
(*f).clone()
};
new_faces.push(nf);
}
// The blend face uses each new edge opposite to its neighbour.
let f1_forward = faces.get(i1).is_some_and(|f| f.boundaries().iter().any(|w| w.edge_iter().any(|e| e.id() == edge.id() && e.front() == &v0)));
let wire: mt::Wire = if f1_forward {
vec![c0.clone(), lb.clone(), c1.inverse(), la.inverse()].into()
} else {
vec![la.clone(), c1.clone(), lb.inverse(), c0.inverse()].into()
};
let blend_face = match shape {
Shape::Flat => builder::try_attach_plane(&[wire]).map_err(|e| KernelError::Failed(format!("chamfer face: {e}")))?,
Shape::Round => {
let swept: mt::Face = builder::tsweep(&c0, v3(p1 - p0));
let mut surf = swept.oriented_surface();
// Outward normal at the arc middle: away from the centre on a convex edge (the
// centre is in the material), toward it on a concave one.
let (c, mid) = (centre(p0), arc_mid(p0));
let outward = (mid - c) * (-side);
use mt::{ParametricSurface3D, SearchParameter};
if let Some((u, v)) = surf.search_parameter(p3(mid), None, 100) {
let nn = surf.normal(u, v);
if Vec3::new(nn.x, nn.y, nn.z).dot(outward) < 0.0 {
surf = mt::Invertible::inverse(&surf);
}
}
mt::Face::try_new(vec![wire], surf).map_err(|e| KernelError::Failed(format!("fillet face: {e}")))?
}
};
new_faces.push(blend_face);
let mut shells = solid.boundaries().clone();
let new_shell: mt::Shell = new_faces.into();
if let Some(sh) = shells.get_mut(si) {
*sh = new_shell;
}
Solid::try_new(shells).map_err(|e| KernelError::Failed(format!("blend produced an invalid solid: {e}")))
}
fn blend(body: &Body, edges: &[Vec3], r: f64, shape: Shape, what: &str) -> Result<Body> {
if !(r.is_finite() && r > 1e-6 && r < 1e6) {
return Err(KernelError::Invalid(format!("{what} size must be positive")));
}
if edges.is_empty() {
return Err(KernelError::Invalid("no edges selected".into()));
}
if edges.len() > 1000 {
return Err(KernelError::Invalid("too many edges".into()));
}
// Coplanar neighbours as one face (as after a join), so corners look as they should.
let mut cur = Body::new(crate::heal::heal_keep(body.deep_copy(), body.size(), body.split_keep()))?;
// Every edge of a convex planar body: rounded as a whole (sphere corners).
if shape == Shape::Round && edges.len() >= 6 {
let solid = cur.deep_copy();
let all = Body::unique_edges(&solid);
if all.len() == edges.len() {
let size = cur.size();
let tol = (size * 2e-3).max(1e-3);
let mut hit = std::collections::HashSet::new();
for p in edges {
if let Some((idx, _)) = cur.nearest_edge(*p, tol)? {
hit.insert(idx);
}
}
if hit.len() == all.len()
&& let Ok(b) = crate::polyhedron::round_all_edges(&cur, r)
{
return Ok(b);
}
}
}
// Whole smooth loops of planar faces are blended in one go, loop by loop.
// Loops and other edges together (every edge of an extruded part): the other edges
// first, which leaves the loops smooth, then the loops.
if let Some((groups, rest)) = loop_split(&cur, edges)?
&& !rest.is_empty()
&& rest.len() < edges.len()
{
let _ = groups;
let loop_pts: Vec<Vec3> = edges.iter().filter(|p| !rest.iter().any(|q| q.dist(**p) < 1e-12)).copied().collect();
cur = blend(&cur, &rest, r, shape, what)?;
return blend(&cur, &loop_pts, r, shape, what);
}
if let Some(groups) = loop_groups(&cur, edges)? {
for g in groups {
let size = cur.size();
let solid = cur.deep_copy();
let ids = edge_ids(&cur, &solid, &g)?;
match crate::loopblend::loop_blend(&solid, &ids, size, r, shape == Shape::Round) {
Some(res) => cur = Body::new(guard(what, || res)?)?,
None => return Err(unsupported("the edges are not a whole loop of a planar face")),
}
}
return Ok(cur);
}
// One at a time, in whatever order works: a run along a planar face's loop (bridging arcs
// that earlier blends left between selected edges, so corners round off), a single edge,
// or a chain of curved edges.
let mut todo: Vec<Vec3> = edges.to_vec();
for _ in 0..(2 * edges.len() + 4) {
if todo.is_empty() {
return Ok(cur);
}
let size = cur.size();
let tol = (size * 2e-3).max(1e-3);
let solid = cur.deep_copy();
if todo.len() >= 2
&& let Some((ids, covered)) = run_on_loop(&cur, &solid, &todo)?
&& let Some(Ok(res)) = crate::loopblend::loop_blend(&solid, &ids, size, r, shape == Shape::Round)
&& let Ok(b) = guard(what, || Ok(res)).and_then(Body::new)
{
cur = b;
todo.retain(|p| !covered.iter().any(|q| q.dist(*p) < 1e-12));
continue;
}
let mut first_err: Option<KernelError> = None;
let mut done: Option<(Body, Vec<usize>)> = None;
for (j, p) in todo.iter().enumerate() {
let Some((idx, dist)) = cur.nearest_edge(*p, tol)? else { return Err(KernelError::Invalid("the body has no edges".into())) };
if dist > size * 0.05 + 1e-3 {
return Err(KernelError::Invalid(format!("no edge near {:?}", [p.x, p.y, p.z])));
}
let edge = Body::unique_edges(&solid).into_iter().nth(idx).ok_or_else(|| KernelError::Invalid("edge index".into()))?;
let attempt = match guard(what, || blend_one(&solid, &edge, size, r, shape)) {
Ok(o) => Ok((o, vec![j])),
// A curved edge, or one between curved faces: roll a ball along its smooth chain.
Err(e) if !curved_case(&solid, &edge) => Err(e),
Err(e) => match smooth_chain(&solid, &edge) {
Some(ids) => {
let on_chain: Vec<usize> = todo
.iter()
.enumerate()
.filter(|(_, q)| {
cur.nearest_edge(**q, tol)
.ok()
.flatten()
.and_then(|(i, _)| Body::unique_edges(&solid).into_iter().nth(i))
.is_some_and(|x| ids.contains(&x.id()))
})
.map(|(i, _)| i)
.collect();
guard(what, || crate::curveblend::curve_blend(&solid, &ids, size, r, shape == Shape::Round))
.map(|o| (o, if on_chain.is_empty() { vec![j] } else { on_chain }))
.map_err(|e2| KernelError::Failed(format!("{e2} ({e})")))
}
None => Err(e),
},
};
match attempt.and_then(|(o, js)| Body::new(o).map(|b| (b, js))) {
Ok(x) => {
done = Some(x);
break;
}
Err(e) => {
if first_err.is_none() {
first_err = Some(e);
}
}
}
}
match done {
Some((b, js)) => {
cur = b;
let mut k = 0;
todo.retain(|_| {
let keep = !js.contains(&k);
k += 1;
keep
});
}
None => return Err(first_err.unwrap_or_else(|| unsupported("these edges"))),
}
}
if todo.is_empty() { Ok(cur) } else { Err(unsupported("blending these edges together")) }
}
/// Neighbouring edges along one boundary loop of a planar face that between them hold at least
/// two of the points' edges, joined by arcs that meet them smoothly (left by earlier blends):
/// the run's edge ids and the points it covers.
#[allow(clippy::type_complexity)]
fn run_on_loop(cur: &Body, solid: &Solid, pts: &[Vec3]) -> Result<Option<(Vec<mt::EdgeID>, Vec<Vec3>)>> {
use mt::{BoundedCurve, ParametricCurve};
let size = cur.size();
let tol = (size * 2e-3).max(1e-3);
let all = Body::unique_edges(solid);
let mut per: Vec<(Vec3, mt::EdgeID)> = Vec::new();
for p in pts {
if let Some((idx, dist)) = cur.nearest_edge(*p, tol)?
&& dist <= size * 0.05 + 1e-3
&& let Some(e) = all.get(idx)
{
per.push((*p, e.id()));
}
}
let dir = |e: &mt::Edge, at_end: bool| -> Option<Vec3> {
let c = e.oriented_curve();
let (t0, t1) = c.range_tuple();
let d = c.der(if at_end { t1 } else { t0 });
Vec3::new(d.x, d.y, d.z).normalized()
};
let mut best: Option<(Vec<mt::EdgeID>, Vec<Vec3>)> = None;
for f in solid.face_iter() {
if !matches!(f.oriented_surface(), mt::Surface::Plane(_)) {
continue;
}
for w in f.boundaries() {
let es: Vec<mt::Edge> = w.edge_iter().cloned().collect();
let m = es.len();
let sel = |i: usize| es.get(i % m).is_some_and(|e| per.iter().any(|(_, id)| *id == e.id()));
// A filler: an unselected arc meeting both neighbours smoothly.
let smooth = |a: &mt::Edge, b: &mt::Edge| match (dir(a, true), dir(b, false)) {
(Some(x), Some(y)) => x.dot(y) > 1.0 - 1e-6,
_ => false,
};
let filler = |i: usize| {
let (Some(prev), Some(e), Some(next)) = (es.get((i + m - 1) % m), es.get(i % m), es.get((i + 1) % m)) else { return false };
!matches!(e.curve(), mt::Curve::Line(_)) && smooth(prev, e) && smooth(e, next)
};
let usable = |i: usize| sel(i) || filler(i);
if (0..m).all(usable) {
// The whole loop.
if (0..m).filter(|i| sel(*i)).count() >= 2 {
let ids: Vec<mt::EdgeID> = es.iter().map(|e| e.id()).collect();
let covered: Vec<Vec3> = per.iter().filter(|(_, id)| ids.contains(id)).map(|(p, _)| *p).collect();
if best.as_ref().is_none_or(|b| covered.len() > b.1.len()) {
best = Some((ids, covered));
}
}
continue;
}
// Runs: start after an unusable edge; trim fillers off both ends.
for s0 in 0..m {
if usable(s0) && !usable(s0 + m - 1) {
let mut idx: Vec<usize> = (0..m).map(|j| s0 + j).take_while(|i| usable(*i)).collect();
while idx.first().is_some_and(|i| !sel(*i)) {
idx.remove(0);
}
while idx.last().is_some_and(|i| !sel(*i)) {
idx.pop();
}
if idx.iter().filter(|i| sel(**i)).count() < 2 {
continue;
}
let ids: Vec<mt::EdgeID> = idx.iter().filter_map(|i| es.get(i % m).map(|e| e.id())).collect();
// Not yet when another selected edge meets one of the run's inner corners:
// that edge goes first, and the run then rounds the corner.
let inner: Vec<mt::Vertex> = idx.iter().skip(1).filter_map(|i| es.get(i % m).map(|e| e.front().clone())).collect();
let blocked = per
.iter()
.filter(|(_, id)| !ids.contains(id))
.any(|(_, id)| all.iter().find(|e| e.id() == *id).is_some_and(|e| inner.iter().any(|v| v == e.front() || v == e.back())));
if blocked {
continue;
}
let covered: Vec<Vec3> = per.iter().filter(|(_, id)| ids.contains(id)).map(|(p, _)| *p).collect();
if best.as_ref().is_none_or(|b| covered.len() > b.1.len()) {
best = Some((ids, covered));
}
}
}
}
}
Ok(best)
}
/// Is the edge curved, or does it lie between faces that aren't both planar?
fn curved_case(solid: &Solid, edge: &mt::Edge) -> bool {
if !matches!(edge.curve(), mt::Curve::Line(_)) {
return true;
}
solid.face_iter().filter(|f| f.edge_iter().any(|e| e.id() == edge.id())).any(|f| !matches!(f.oriented_surface(), mt::Surface::Plane(_)))
}
/// The chain of edges continuing `edge` smoothly at its ends (its ids): closed, or open where
/// the next edge turns sharply.
fn smooth_chain(solid: &Solid, edge: &mt::Edge) -> Option<Vec<mt::EdgeID>> {
use mt::{BoundedCurve, ParametricCurve};
let all = Body::unique_edges(solid);
let dir = |e: &mt::Edge, at_end: bool| -> Option<Vec3> {
let c = e.curve();
let (t0, t1) = c.range_tuple();
let d = c.der(if at_end { t1 } else { t0 });
Vec3::new(d.x, d.y, d.z).normalized()
};
let mut ids = vec![edge.id()];
// Walk on from one end of the edge (leaving vertex `v` in direction `d`).
let walk = |mut v: mt::Vertex, mut d: Vec3, ids: &mut Vec<mt::EdgeID>, stop: &mt::Vertex| -> Option<bool> {
for _ in 0..200 {
if v == *stop {
return Some(true);
}
let next = all.iter().filter(|e| !ids.contains(&e.id()) && (*e.front() == v || *e.back() == v)).find_map(|e| {
let fwd = *e.front() == v;
let t = if fwd { dir(e, false)? } else { -dir(e, true)? };
(t.dot(d) > 1.0 - 1e-4).then(|| (e.clone(), fwd))
});
let Some((e, fwd)) = next else { return Some(false) };
ids.push(e.id());
if fwd {
v = e.back().clone();
d = dir(&e, true)?;
} else {
v = e.front().clone();
d = -dir(&e, false)?;
}
}
None
};
let closed = walk(edge.back().clone(), dir(edge, true)?, &mut ids, edge.front())?;
if !closed {
walk(edge.front().clone(), -dir(edge, false)?, &mut ids, edge.back())?;
}
Some(ids)
}
fn edge_mid(e: &mt::Edge) -> Option<Vec3> {
use mt::{BoundedCurve, ParametricCurve};
let c = e.curve();
let (t0, t1) = c.range_tuple();
Some(from_p3(c.subs((t0 + t1) * 0.5)))
}
/// Do the loop's edges meet tangentially everywhere?
fn smooth_loop(w: &mt::Wire) -> bool {
use mt::{BoundedCurve, ParametricCurve};
let es: Vec<mt::Edge> = w.edge_iter().cloned().collect();
let n = es.len();
let dir = |e: &mt::Edge, at_end: bool| -> Option<Vec3> {
let c = e.oriented_curve();
let (t0, t1) = c.range_tuple();
let t = if at_end { t1 } else { t0 };
let d = c.der(t);
Vec3::new(d.x, d.y, d.z).normalized()
};
(0..n).all(|i| match (es.get(i), es.get((i + 1) % n)) {
(Some(a), Some(b)) => match (dir(a, true), dir(b, false)) {
(Some(x), Some(y)) => x.dot(y) > 1.0 - 1e-6,
_ => false,
},
_ => false,
})
}
/// The B-rep edges nearest the points (each once).
fn edge_ids(cur: &Body, solid: &Solid, pts: &[Vec3]) -> Result<Vec<mt::EdgeID>> {
let size = cur.size();
let tol = (size * 2e-3).max(1e-3);
let all = Body::unique_edges(solid);
let mut ids = Vec::new();
for p in pts {
if let Some((idx, dist)) = cur.nearest_edge(*p, tol)?
&& dist <= size * 0.05 + 1e-3
&& let Some(e) = all.get(idx)
&& !ids.contains(&e.id())
{
ids.push(e.id());
}
}
Ok(ids)
}
/// When the edges make up whole boundary loops of planar faces: the edge points per loop.
fn loop_groups(cur: &Body, pts: &[Vec3]) -> Result<Option<Vec<Vec<Vec3>>>> {
Ok(loop_split(cur, pts)?.and_then(|(g, rest)| rest.is_empty().then_some(g)))
}
/// Edges in whole loops of planar faces (points per loop), and the other edges' points.
fn loop_split(cur: &Body, pts: &[Vec3]) -> Result<Option<(Vec<Vec<Vec3>>, Vec<Vec3>)>> {
let solid = cur.deep_copy();
let size = cur.size();
let tol = (size * 2e-3).max(1e-3);
let all = Body::unique_edges(&solid);
// Each point's edge. A point on a vertex is as near to the edges meeting there (a circle
// and a cylinder's seam line): prefer one on a planar face's boundary.
let polys = cur.edges(tol)?;
let planar_edge: std::collections::HashSet<mt::EdgeID> = solid
.face_iter()
.filter(|f| matches!(f.oriented_surface(), mt::Surface::Plane(_)))
.flat_map(|f| f.edge_iter().map(|e| e.id()).collect::<Vec<_>>())
.collect();
let mut per: Vec<(Vec3, mt::EdgeID)> = Vec::new();
for p in pts {
let dists: Vec<(usize, f64)> =
polys.iter().map(|e| (e.index, e.points.windows(2).map(|w| p.dist_to_segment(w[0], w[1])).fold(f64::INFINITY, f64::min))).collect();
let best = dists.iter().map(|x| x.1).fold(f64::INFINITY, f64::min);
if best > size * 0.05 + 1e-3 {
return Ok(None);
}
let near: Vec<&mt::Edge> = dists.iter().filter(|x| x.1 <= best + tol).filter_map(|x| all.get(x.0)).collect();
let Some(e) = near.iter().find(|e| planar_edge.contains(&e.id())).or(near.first()) else { return Ok(None) };
per.push((*p, e.id()));
}
let ids: Vec<mt::EdgeID> = per.iter().map(|x| x.1).collect();
let mut covered: Vec<mt::EdgeID> = Vec::new();
let mut groups = Vec::new();
for f in solid.face_iter() {
if !matches!(f.oriented_surface(), mt::Surface::Plane(_)) {
continue;
}
for w in f.boundaries() {
let wids: Vec<mt::EdgeID> = w.edge_iter().map(|e| e.id()).collect();
if wids.iter().any(|x| covered.contains(x)) {
continue;
}
// The whole loop is selected, or one of its edges and the loop is smooth (tangent
// chain, which also covers a circle that a boolean left in pieces).
let all_sel = wids.iter().all(|x| ids.contains(x));
let some_sel = wids.iter().any(|x| ids.contains(x));
if all_sel || (some_sel && smooth_loop(&w)) {
covered.extend(wids.iter().copied());
// One point per loop edge, on it.
let pts: Vec<Vec3> = w.edge_iter().filter_map(edge_mid).collect();
groups.push(pts);
}
}
}
let rest: Vec<Vec3> = per.iter().filter(|(_, id)| !covered.contains(id)).map(|(p, _)| *p).collect();
Ok((!groups.is_empty()).then_some((groups, rest)))
}
/// Constant-radius fillet of the edges nearest to the given points.
pub fn fillet(body: &Body, edges: &[Vec3], radius: f64) -> Result<Body> {
body.require_brep("fillet")?;
// Corners the local blends refuse (an earlier round at an edge's end): radius per edge.
blend(body, edges, radius, Shape::Round, "fillet").or_else(|e| {
let sel: Vec<(Vec3, f64)> = edges.iter().map(|p| (*p, radius)).collect();
crate::blend_corner::fillet_radii(body, &sel).map_err(|_| e)
})
}
/// Equal-distance chamfer of the edges nearest to the given points. Each edge is cut with a
/// prism whose only face inside the body is the chamfer plane (so neighbouring chamfers meet in
/// a mitre); the local operation is the fallback.
pub fn chamfer(body: &Body, edges: &[Vec3], distance: f64) -> Result<Body> {
body.require_brep("chamfer")?;
if !(distance.is_finite() && distance > 1e-6 && distance < 1e6) {
return Err(KernelError::Invalid("chamfer size must be positive".into()));
}
if edges.is_empty() || edges.len() > 1000 {
return Err(KernelError::Invalid("select 1…1000 edges".into()));
}
// All cutters at once (their union mitres the corners), else one edge at a time.
let tools: Result<Vec<Body>> = edges.iter().enumerate().map(|(i, p)| chamfer_tool(body, *p, distance, i)).collect();
if let Ok(tools) = tools {
let mut acc: Option<Body> = None;
let mut ok = true;
for t in tools {
let next = match &acc {
None => Some(t),
Some(a) => crate::ops::boolean(a, &t, crate::BoolOp::Union).ok().flatten(),
};
if next.is_none() {
ok = false;
break;
}
acc = next;
}
if ok
&& let Some(tool) = acc
&& let Ok(Some(r)) = crate::ops::boolean(body, &tool, crate::BoolOp::Cut)
{
return Ok(r);
}
}
// At a pocket rim the cutters cannot extend beyond the selected edges. Rebuild
// the corners locally, allowing adjacent chamfers to reach different depths
// on their common wall seam.
if edges.len() > 1
&& let Ok(result) = crate::blend_corner::chamfer(body, edges, distance)
{
return Ok(result);
}
// Coplanar neighbours as one face (as after a join), so corners look as they should.
let mut cur = Body::new(crate::heal::heal_keep(body.deep_copy(), body.size(), body.split_keep()))?;
if let Some(groups) = loop_groups(&cur, edges)? {
for g in groups {
let size = cur.size();
let solid = cur.deep_copy();
let ids = edge_ids(&cur, &solid, &g)?;
match crate::loopblend::loop_blend(&solid, &ids, size, distance, false) {
Some(res) => cur = Body::new(guard("chamfer", || res)?)?,
None => return Err(unsupported("the edges are not a whole loop of a planar face")),
}
}
return Ok(cur);
}
for p in edges {
cur = match chamfer_tool(&cur, *p, distance, 0).and_then(|t| crate::ops::boolean(&cur, &t, crate::BoolOp::Cut)) {
Ok(Some(b)) => b,
_ => blend(&cur, std::slice::from_ref(p), distance, Shape::Flat, "chamfer")?,
};
}
Ok(cur)
}
/// Geometry of a straight convex edge between two planar faces.
struct EdgeFrame {
p0: Vec3,
p1: Vec3,
d: Vec3,
n1: Vec3,
n2: Vec3,
t1: Vec3,
t2: Vec3,
}
fn edge_frame(cur: &Body, p: Vec3) -> Result<EdgeFrame> {
let size = cur.size();
let tol = (size * 2e-3).max(1e-3);
let Some((idx, dist)) = cur.nearest_edge(p, tol)? else { return Err(KernelError::Invalid("the body has no edges".into())) };
if dist > size * 0.05 + 1e-3 {
return Err(KernelError::Invalid(format!("no edge near {:?}", [p.x, p.y, p.z])));
}
let solid = &*cur.solid;
let edge = Body::unique_edges(solid).into_iter().nth(idx).ok_or_else(|| KernelError::Invalid("edge index".into()))?;
if !matches!(edge.curve(), mt::Curve::Line(_)) {
return Err(unsupported("only straight edges"));
}
let faces: Vec<&mt::Face> = solid.face_iter().filter(|f| f.edge_iter().any(|e| e.id() == edge.id())).collect();
let [f1, f2] = faces[..] else { return Err(unsupported("the edge is not between two faces")) };
let (Some(n1), Some(n2)) = (plane_normal(f1), plane_normal(f2)) else { return Err(unsupported("both faces next to the edge must be planar")) };
let (p0, p1) = (vtx(edge.absolute_front()), vtx(edge.absolute_back()));
let d = (p1 - p0).normalized().ok_or_else(|| KernelError::Failed("zero-length edge".into()))?;
let mut t1 = n1.cross(d);
if t1.dot(n2) > 0.0 {
t1 = -t1;
}
let mut t2 = n2.cross(d);
if t2.dot(n1) > 0.0 {
t2 = -t2;
}
if n1.dot(t2) > 1e-9 || n2.dot(t1) > 1e-9 || t1.dot(t2) < -1.0 + 1e-6 {
return Err(unsupported("only convex edges"));
}
Ok(EdgeFrame { p0, p1, d, n1, n2, t1, t2 })
}
/// The prism that cuts a chamfer of size `s` on the edge nearest `p`. `k` varies the parts that
/// stay outside the body so that neighbouring cutters don't share edges.
/// The second side of an unequal chamfer: a distance along the other face, or the angle the
/// chamfer makes with the first face.
#[derive(Clone, Copy, Debug, PartialEq)]
pub enum ChamferSide {
Distance(f64),
Angle(f64),
}
/// A chamfer with different setbacks on the two faces of each (straight) edge: `d1` along the
/// first face (the one facing up most, the other with `flip`), the second side by distance or
/// angle.
pub fn chamfer_sides(body: &Body, edges: &[Vec3], d1: f64, side: ChamferSide, flip: bool) -> Result<Body> {
body.require_brep("chamfer")?;
let ok = |x: f64| x.is_finite() && x > 1e-6 && x < 1e6;
let valid = ok(d1)
&& match side {
ChamferSide::Distance(d) => ok(d),
ChamferSide::Angle(a) => a.is_finite() && a > 1e-3 && a < std::f64::consts::PI - 1e-3,
};
if !valid {
return Err(KernelError::Invalid("chamfer sizes must be positive (the angle within 0°…180°)".into()));
}
if edges.is_empty() || edges.len() > 1000 {
return Err(KernelError::Invalid("select 1…1000 edges".into()));
}
let mut cur = body.clone();
for (k, p) in edges.iter().enumerate() {
let t = chamfer_tool_sides(&cur, *p, d1, Some((side, flip)), k)?;
cur = crate::ops::boolean(&cur, &t, crate::BoolOp::Cut)?.ok_or_else(|| KernelError::Failed("the chamfer removed everything".into()))?;
}
Ok(cur)
}
pub(crate) fn chamfer_tool(cur: &Body, p: Vec3, s: f64, k: usize) -> Result<Body> {
chamfer_tool_sides(cur, p, s, None, k)
}
fn chamfer_tool_sides(cur: &Body, p: Vec3, s: f64, sides: Option<(ChamferSide, bool)>, k: usize) -> Result<Body> {
let mut f = edge_frame(cur, p)?;
// Setbacks along each face: equal, or by the second side's rule.
let (s1, s2) = match sides {
None => (s, s),
Some((side, flip)) => {
// Side 1: the face facing up most (then +y, +x), unless flipped.
let up = Vec3::new(1e-6, 1e-3, 1.0);
if (f.n2.dot(up) > f.n1.dot(up)) != flip {
std::mem::swap(&mut f.n1, &mut f.n2);
std::mem::swap(&mut f.t1, &mut f.t2);
}
let s2 = match side {
ChamferSide::Distance(d) => d,
ChamferSide::Angle(a) => {
// The triangle edge–A–B: angle φ at the edge, `a` at A (on face 1).
let phi = f.t1.dot(f.t2).clamp(-1.0, 1.0).acos();
let den = (phi + a).sin();
if den <= 1e-9 {
return Err(KernelError::Invalid("that chamfer angle runs past the other face".into()));
}
s * a.sin() / den
}
};
(s, s2)
}
};
let s = s1.max(s2);
let size = cur.size();
let len = f.p0.dist(f.p1);
let ext = (s * 2.0).max(size * 0.01) * (1.0 + 0.093 * (k % 5) as f64);
// Cross-section at p0 - d*ext, in a plane with normal d.
let base = f.p0 - f.d * ext;
let plane = solvecraft_geom::Plane::from_normal(base, f.d).ok_or_else(|| KernelError::Failed("chamfer plane".into()))?;
let a = base + f.t1 * s1;
let b = base + f.t2 * s2;
let ab = (a - b).normalized().ok_or_else(|| KernelError::Failed("chamfer".into()))?;
let out = (f.n1 + f.n2).normalized().ok_or_else(|| KernelError::Failed("chamfer".into()))?;
let vary = 1.0 + 0.137 * (k % 7) as f64;
let reach = (s * 4.0 + size * 0.02) * vary;
let a_ext = a + ab * (s * 0.5 + reach * 0.05);
let b_ext = b - ab * (s * 0.5 + reach * 0.07);
let e_far = base + out * reach;
// The material beyond both ends must be empty (the cutter runs past them).
let mid = (a + b + base) / 3.0;
for probe in [mid + f.d * (ext * 0.5), mid + f.d * (len + ext * 1.5)] {
if cur.contains(probe) {
return Err(unsupported("chamfers ending at a concave corner"));
}
}
let loc: Vec<solvecraft_geom::Vec2> = [a_ext, b_ext, e_far].iter().map(|q| plane.to_local(*q)).collect();
let mut lp = solvecraft_geom::Loop2::polygon(&loc);
if lp.signed_area() < 0.0 {
lp = lp.reversed();
}
let region = solvecraft_geom::Region2 { outer: lp, holes: vec![] };
crate::build::extrude(&plane, &[region], 0.0, len + 2.0 * ext)?.pop().ok_or_else(|| KernelError::Failed("chamfer tool".into()))
}
#[cfg(test)]
mod tests {
use super::*;
use solvecraft_geom::{Loop2, Plane, Region2, Vec2};
#[test]
fn chamfer_extension_cannot_cross_a_hole_and_reenter_the_face() {
let rectangle = |a, b, c, d| Loop2::polygon(&[Vec2::new(a, b), Vec2::new(c, b), Vec2::new(c, d), Vec2::new(a, d)]);
let region =
Region2 { outer: rectangle(0.0, 0.0, 10.0, 10.0), holes: vec![rectangle(4.0, 4.0, 6.0, 6.0), Loop2::circle(Vec2::new(4.0, 1.5), 0.25)] };
for plane in [Plane::XY, Plane::XZ] {
let face = crate::build::face(&plane, &region).unwrap();
let p = plane.to_world(Vec2::new(4.0, 4.0));
let fits = |y| extension_fits(&face, p, plane.to_world(Vec2::new(4.0, y)), 1e-6);
assert!(fits(2.0));
assert!(!fits(1.5)); // endpoint in the circular hole
assert!(!fits(0.5)); // endpoint in material, but the extension crossed the hole
assert!(!fits(-1e8)); // an arbitrarily long slide cannot escape the face
}
}
#[test]
fn local_chamfer_intersects_sloped_end_planes() {
for slope in [-0.5, 0.5] {
let region = Region2 {
outer: Loop2::polygon(&[Vec2::ZERO, Vec2::new(40.0, 0.0), Vec2::new(40.0 - slope * 20.0, 20.0), Vec2::new(slope * 20.0, 20.0)]),
holes: vec![],
};
let body = crate::extrude(&Plane::XY, &[region], 0.0, 20.0).unwrap().pop().unwrap();
let pick = [Vec3::new(20.0, 0.0, 20.0)];
let result = blend(&body, &pick, 2.0, Shape::Flat, "chamfer").unwrap();
let removed = 2.0 * (40.0 - 2.0 * slope * 2.0 / 3.0);
let actual = crate::measure(&body).unwrap().volume - crate::measure(&result).unwrap().volume;
assert!((actual - removed).abs() < 1e-6, "{actual} vs {removed}");
assert!(result.validity().is_empty());
// The new corner vertices lie on both original end planes.
for point in [Vec3::new(slope * 2.0, 2.0, 20.0), Vec3::new(40.0 - slope * 2.0, 2.0, 20.0)] {
assert!(result.solid.vertex_iter().any(|v| vtx(&v).dist(point) < 1e-8));
}
assert!(blend(&body, &pick, 25.0, Shape::Flat, "chamfer").is_err());
// Oblique fillet caps need elliptical trims, which this local path does not build.
assert!(blend(&body, &pick, 2.0, Shape::Round, "fillet").is_err());
}
}
}