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fix(geometry): tighten circumscribed flattening; stop padding the validator

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The Clipper validator flagged valid Opus55 and PEP layouts (P260805-03,
P260626-03). Two causes:

- Arc.ToPoints(circumscribe) scales every vertex out by 1/cos(step/2),
  endpoints included, so a 0.03125 corner fillet flattened at 0.01 poked
  0.013 past the straight edges it meets. ClipperBridge now flattens itself:
  circumscribed arcs keep their endpoints on the arc and put interior
  vertices on tangent intersections, with the segment count chosen so the
  outward error stays within the tolerance. Arc.ToPoints is unchanged for
  its other callers.
- The conservative padding made a layout exactly at the spacing fail.
  NestValidator now uses OffsetForValidation: the same conservative
  flattening, round joins at a tenth of the tolerance, no padding. Its only
  leniency is that join chord error at convex corners.

With both, Opus55 is valid on all 26 benchmark jobs (25 before the
Clipper migration; the old failure was a spike artifact).

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
This commit is contained in:
aj
2026-09-23 10:40:59 -04:00
co-authored by Claude Opus 5.5
parent 9af97c70b0
commit 062c7fa08f
4 changed files with 231 additions and 9 deletions
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@@ -134,7 +134,7 @@ Always keep `README.md` and `CLAUDE.md` up to date when making changes that affe
- Angles throughout the codebase are in **radians** (use `Angle.ToRadians()`/`Angle.ToDegrees()` for conversion).
- `Tolerance.Epsilon` is used for floating-point comparisons across geometry operations.
- Nesting uses async progress/cancellation: `IProgress<NestProgress>` and `CancellationToken` flow through the engine to the UI's `NestProgressForm`.
- **Spacing offsets**: polygon consumers (`PolygonHelper`, `PartBoundary`, `NestValidator`, `CutOff`, the `LayoutPart` Draw Offset display) use `ClipperBridge.Offset`/`OffsetPerimeter`: one Clipper pass over the flattened region (perimeter positive, cutouts negative) with round joins at 1e-4 precision, so features narrower than twice the spacing collapse and closed-up holes disappear. `circumscribe: true` is the conservative mode (perimeter arcs circumscribed, cutout arcs inscribed, inflation padded by the join chord error) and never under-estimates the spacing. `PartGeometry.GetOffsetPerimeterEntities`/`GetOffsetPartEntities` stay on the arc-preserving per-entity `Shape.OffsetOutward`/`OffsetInward` (internal) because directional-distance loops are much faster on native arcs; their chains are closed but may keep zero-area spikes inside the envelope. Clipper is allowed only for cached CPU preparation, never in per-pair hot loops.
- **Spacing offsets**: polygon consumers (`PolygonHelper`, `PartBoundary`, `NestValidator`, `CutOff`, the `LayoutPart` Draw Offset display) use `ClipperBridge.Offset`/`OffsetPerimeter`: one Clipper pass over the flattened region (perimeter positive, cutouts negative) with round joins at 1e-4 precision, so features narrower than twice the spacing collapse and closed-up holes disappear. `circumscribe: true` is the conservative mode (perimeter arcs circumscribed with endpoints kept on the arc, cutout arcs inscribed, inflation padded by the join chord error) and never under-estimates the spacing. `NestValidator` uses `OffsetForValidation` instead: the same flattening with fine joins and no padding, so a layout exactly at the spacing passes. `PartGeometry.GetOffsetPerimeterEntities`/`GetOffsetPartEntities` stay on the arc-preserving per-entity `Shape.OffsetOutward`/`OffsetInward` (internal) because directional-distance loops are much faster on native arcs; their chains are closed but may keep zero-area spikes inside the envelope. Clipper is allowed only for cached CPU preparation, never in per-pair hot loops.
- `Compactor` performs post-fill gravity compaction — after filling, parts are pushed toward a plate edge using directional distance calculations to close gaps between irregular shapes.
- `FillScore` uses lexicographic comparison (count > utilization > compactness) to rank fill results consistently across all fill strategies.
- **Cut-off materialization lifecycle**: `CutOff` objects live on `Plate.CutOffs`. Each generates a `Drawing` (with `IsCutOff = true`) whose `Program` contains trimmed line segments. `Plate.RegenerateCutOffs(settings)` removes old cut-off Parts, recomputes programs, and re-adds them to `Plate.Parts`. Regeneration triggers: cut-off add/remove/move, part drag complete, fill complete, plate transform. Cut-off Parts are excluded from quantity tracking, utilization, overlap detection, and nest file serialization (programs are regenerated from definitions on load).