fix(engine): allow 0.0005 spacing slack in layout validation

Layouts placed exactly at the part spacing can land ~1e-4 short once
rotated, rounded (e.g. PEP's 4-decimal exports) and snapped to the
Clipper grid, so both validators rejected layouts that were correct in
practice. NestTolerances.SpacingSlack (0.0005, far below anything a
cutting machine resolves) is now subtracted from the spacing by
NestLayoutCheck's inflation and NestJobPlacementValidator's edge-distance
check. The frozen LegacyNestValidator takes the same rule so the
equivalence tests keep comparing like with like.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>

CLAUDE.md

@@ -137,7 +137,7 @@ 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 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.
+- **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, inflated by the spacing less `NestTolerances.SpacingSlack` (0.0005), so a layout exactly at the spacing passes even after rotation and coordinate rounding leave it ~1e-4 short. `NestJobPlacementValidator` applies the same slack to its edge-distance check. `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.
 - **Marks are not material**: scribe/etch moves are marked on the surface, never cut through, so they are left out of nesting. `SpecialLayers.IsMaterial(layer)` (excludes `Rapid` and `Scribe`) is the filter for every consumer that builds part material from a program: drawing area, canonical angle, part collision, `PartGeometry`, plate perimeters, best-fit/pair evaluation, rotation analysis, the GPU evaluators, and both validators (`NestJobPlacementValidator`, benchmark `NestValidator`). Cutting time, on-screen display, splitting, and post-processors still see marks. Older `.nest` files (e.g. `tools/PepNestExport` output) saved etch as cut moves while their source entities kept the `SCRIBE` layer; `NestReader` runs `ScribeLayerRepair` on load to move matching program moves back to `Scribe`.
 - `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.

OpenNest.Engine.Tests/Jobs/NestJobSpacingValidationTests.cs

@@ -15,7 +15,6 @@ namespace OpenNest.Engine.Tests.Jobs;
 public class NestJobSpacingValidationTests
 {
     private const double Spacing = 0.25;
-    private const double Epsilon = 0.0000001;
     private const double Origin = 50;
 
     public static IEnumerable<object[]> Shapes() =>
@@ -98,6 +97,27 @@ public class NestJobSpacingValidationTests
         ));
     }
 
+    [Theory]
+    [InlineData(0.0001, true)]
+    [InlineData(0.0004, true)]
+    [InlineData(0.0010, false)]
+    public void GapsJustUnderSpacingPassWithinTheSlack(double shortfall, bool expected)
+    {
+        // A layout placed at the spacing can land ~1e-4 short once rotated and rounded.
+        var program = TestDrawingFactory.Rectangle(4, 3);
+        var part = new NestJobPart("part", PartGeometrySnapshot.FromProgram(program), 2);
+        var job = new NestJob(
+            new[] { part },
+            new[] { new NestPlateStock("stock", new Size(200, 200), 1, Spacing) }
+        );
+        var first = new NestJobPlacement("part", 0, Origin, Origin, 0);
+        var second = new NestJobPlacement("part", 1, Origin + 4 + Spacing - shortfall, Origin, 0);
+
+        Assert.Equal(expected, IsValid(job, first, second));
+        var geometry = JobPartGeometry.Read(part.Geometry);
+        Assert.Equal(expected, NestLayoutCheck.Clears(geometry, first, geometry, second, Spacing));
+    }
+
     private static bool IsValid(NestJob job, params NestJobPlacement[] placements)
     {
         try
@@ -123,7 +143,7 @@ public class NestJobSpacingValidationTests
         if (Collision.HasOverlap(a[0], b[0], a.Skip(1).ToList(), b.Skip(1).ToList()))
             return true;
 
-        var limit = Spacing - Epsilon;
+        var limit = Spacing - NestTolerances.SpacingSlack;
         foreach (var left in a)
         {
             var leftLines = left.ToLines();

OpenNest.Engine/Jobs/NestJobPlacementValidator.cs

@@ -66,7 +66,8 @@ internal static class NestJobPlacementValidator
                     continue;
                 if (Overlaps(shape, other))
                     throw new InvalidOperationException("Candidate placements overlap.");
-                if (stock.PartSpacing > 0 && Distance(shape, other) < stock.PartSpacing - Epsilon)
+                if (stock.PartSpacing > 0
+                    && Distance(shape, other) < stock.PartSpacing - NestTolerances.SpacingSlack)
                     throw new InvalidOperationException(
                         "Candidate placements violate required part spacing."
                     );

OpenNest.Engine/Jobs/NestLayoutCheck.cs

@@ -52,7 +52,8 @@ public static class NestLayoutCheck
             (al, bl) = (bl, al);
             (ar, br) = (br, ar);
         }
-        var inflated = spacing > Tolerance.Epsilon ? Outline(ap, al, spacing) : ar;
+        var inflateBy = InflationFor(spacing);
+        var inflated = inflateBy > Tolerance.Epsilon ? Outline(ap, al, inflateBy) : ar;
         return !BoxesTouch(inflated.Perimeter.BoundingBox, br.Perimeter.BoundingBox)
             || !Overlaps(inflated, br);
     }
@@ -289,11 +290,12 @@ public static class NestLayoutCheck
     {
         var raw = new PartOutline[parts.Count];
         var inflated = new PartOutline[parts.Count];
+        var inflateBy = InflationFor(spacing);
 
         for (var i = 0; i < parts.Count; i++)
         {
             raw[i] = Outline(parts[i], 0);
-            inflated[i] = spacing > Tolerance.Epsilon ? Outline(parts[i], spacing) : raw[i];
+            inflated[i] = inflateBy > Tolerance.Epsilon ? Outline(parts[i], inflateBy) : raw[i];
         }
 
         var order = Enumerable
@@ -339,6 +341,10 @@ public static class NestLayoutCheck
             .GetBoundingBox()
             .Translate(part.Location);
 
+    /// <summary>Inflation that enforces <paramref name="spacing"/> less the shared slack.</summary>
+    private static double InflationFor(double spacing) =>
+        System.Math.Max(0, spacing - NestTolerances.SpacingSlack);
+
     private static bool BoxesTouch(Box a, Box b) =>
         a.Left <= b.Right + Tolerance.Epsilon
         && b.Left <= a.Right + Tolerance.Epsilon
@@ -398,9 +404,10 @@ public static class NestLayoutCheck
     /// that closes up under the offset is dropped, which treats it as solid:
     /// conservative, since it has no room for another part at the required
     /// spacing anyway. Arcs are flattened conservatively (perimeter arcs
-    /// circumscribed, cutout arcs inscribed) but nothing is padded, so a layout
-    /// exactly at the spacing passes; the only leniency is the round-join chord
-    /// error at convex corners (OutlineTolerance / 10).
+    /// circumscribed, cutout arcs inscribed) but nothing is padded. Callers inflate
+    /// by the spacing less NestTolerances.SpacingSlack, so a layout exactly at the
+    /// spacing passes despite rounding; the only other leniency is the round-join
+    /// chord error at convex corners (OutlineTolerance / 10).
     /// part.Program is already rotated; only a Location offset is needed.
     /// </summary>
     private static PartOutline Outline(Part part, double inflateBy)

OpenNest.Engine/Jobs/NestTolerances.cs

@@ -12,6 +12,12 @@ public static class NestTolerances
     /// perimeter arcs and inscribes cutouts; the placement validator uses inscribed arcs.</summary>
     public const double ValidationOutline = 0.001;
 
+    /// <summary>How far under the part spacing a gap may fall and still pass both validators.
+    /// Layouts placed exactly at the spacing land up to ~1e-4 short once rotated, rounded
+    /// coordinates (e.g. PEP's 4-decimal exports) meet the Clipper grid; 0.0005 covers that
+    /// with margin and is far below anything a cutting machine can resolve.</summary>
+    public const double SpacingSlack = 0.0005;
+
     /// <summary>Clipper decimal precision (a 1e-4 coordinate grid).</summary>
     public const int ClipperPrecision = ClipperBridge.Precision;
 

OpenNest.Tests/Benchmark/LegacyNestValidator.cs

@@ -251,10 +251,13 @@ namespace OpenNest.Tests.Benchmark
             var raw = new PartOutline[parts.Count];
             var inflated = new PartOutline[parts.Count];
 
+            // The one intended rule change since the freeze: the shared spacing slack.
+            var inflateBy = System.Math.Max(0, spacing - NestTolerances.SpacingSlack);
+
             for (var i = 0; i < parts.Count; i++)
             {
                 raw[i] = Outline(parts[i], 0);
-                inflated[i] = spacing > Tolerance.Epsilon ? Outline(parts[i], spacing) : raw[i];
+                inflated[i] = inflateBy > Tolerance.Epsilon ? Outline(parts[i], inflateBy) : raw[i];
             }
 
             var order = Enumerable