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feat: replace Clipper2 with direct entity splitting in DrawingSplitter

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Replace polygon boolean clipping with direct entity splitting using
bounding box filtering and exact intersection math. Eliminates Clipper2
precision drift that caused contour gaps (0.0035") breaking area
calculation and ShapeBuilder chaining.

Also fixes SpikeGrooveSplit: spike depth is now grooveDepth + weldGap
(spike protrudes past groove), both V-shapes use same angle formula,
and weldGap no longer double-subtracted from tip depth.

SplitDrawingForm: fix parameter mapping (GrooveDepth direct from nud,
not inflated), remove redundant Spike Depth display, add feature
contour preview and trimmed split lines at feature positions.

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
This commit is contained in:
AJ Isaacs
2026-03-24 18:19:47 -04:00
parent df18b72881
commit 39f8a79cfd
5 changed files with 531 additions and 230 deletions
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14
OpenNest.Core/Splitting/SpikeGrooveSplit.cs
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@@ -7,6 +7,7 @@ namespace OpenNest;
/// Generates interlocking spike/V-groove pairs along the split edge.
/// Spikes protrude from the positive side into the negative side.
/// V-grooves on the negative side receive the spikes for self-alignment during welding.
/// The weld gap (grooveDepth - spikeDepth) is the clearance at the tip when assembled.
/// </summary>
public class SpikeGrooveSplit : ISplitFeature
{
@@ -18,7 +19,6 @@ public class SpikeGrooveSplit : ISplitFeature
var pairCount = parameters.SpikePairCount;
var spikeDepth = parameters.SpikeDepth;
var grooveDepth = parameters.GrooveDepth;
var weldGap = parameters.SpikeWeldGap;
var angleRad = OpenNest.Math.Angle.ToRadians(parameters.SpikeAngle / 2);
var spikeHalfWidth = spikeDepth * System.Math.Tan(angleRad);
var grooveHalfWidth = grooveDepth * System.Math.Tan(angleRad);
@@ -44,10 +44,8 @@ public class SpikeGrooveSplit : ISplitFeature
pairPositions.Add(extentStart + margin + usable * i / (pairCount - 1));
}
// Groove side: V-groove cut deeper than the spike so the spike fits inside
var negEntities = BuildGrooveSide(pairPositions, grooveHalfWidth, grooveDepth, extentStart, extentEnd, pos, isVertical);
// Spike side: spike protrudes but stops short of the split line by weldGap
var posEntities = BuildSpikeSide(pairPositions, spikeHalfWidth, spikeDepth, weldGap, extentStart, extentEnd, pos, isVertical);
var posEntities = BuildSpikeSide(pairPositions, spikeHalfWidth, spikeDepth, extentStart, extentEnd, pos, isVertical);
return new SplitFeatureResult(negEntities, posEntities);
}
@@ -79,10 +77,8 @@ public class SpikeGrooveSplit : ISplitFeature
}
private static List<Entity> BuildSpikeSide(List<double> pairPositions, double halfWidth, double depth,
double weldGap, double extentStart, double extentEnd, double pos, bool isVertical)
double extentStart, double extentEnd, double pos, bool isVertical)
{
// Spike tip stops short of the split line by weldGap
var tipDepth = depth - weldGap;
var entities = new List<Entity>();
var cursor = extentEnd;
@@ -95,8 +91,8 @@ public class SpikeGrooveSplit : ISplitFeature
if (cursor > spikeEnd + OpenNest.Math.Tolerance.Epsilon)
entities.Add(MakeLine(pos, cursor, pos, spikeEnd, isVertical));
entities.Add(MakeLine(pos, spikeEnd, pos - tipDepth, center, isVertical));
entities.Add(MakeLine(pos - tipDepth, center, pos, spikeStart, isVertical));
entities.Add(MakeLine(pos, spikeEnd, pos - depth, center, isVertical));
entities.Add(MakeLine(pos - depth, center, pos, spikeStart, isVertical));
cursor = spikeStart;
}