feat(cutting): tab parts by width when the plate has no support bed

With support tabs on and no support bed, nothing was tabbed and nothing
said so. A new no-bed width range (NoBedTabMinWidth..NoBedTabMaxWidth,
the short side of the part's minimum-area bounding rectangle) now picks
the parts to tab instead. SupportTabSettings.Analyze makes the choice
for Plan Cutting, hand-placed lead-ins and the pre-post review; without
a bed any tab clear of inside corners counts. With no bed and no range,
the plan notes that nothing was tabbed. Cutting Settings > Tabs gains
the range fields, and the values persist with the cutting parameters.

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

OpenNest.Core/CNC/CuttingPlanning/OwnedCuttingParameters.cs

@@ -42,6 +42,8 @@ internal static class OwnedCuttingParameters
                 : CopyTab(source.TabConfig),
             TabsEnabled = source.TabsEnabled,
             SupportTabs = source.SupportTabs,
+            NoBedTabMinWidth = Dimension(source.NoBedTabMinWidth),
+            NoBedTabMaxWidth = Dimension(source.NoBedTabMaxWidth),
             Sequencing = new SequenceParameters
             {
                 Method = sequence.Method,

OpenNest.Core/CNC/CuttingPlanning/StateFingerprint.cs

@@ -90,6 +90,8 @@ internal static class StateFingerprint
             TabSettings(p.TabConfig);
             Flag(p.TabsEnabled);
             Flag(p.SupportTabs);
+            Number(p.NoBedTabMinWidth);
+            Number(p.NoBedTabMaxWidth);
             Sequence(p.Sequencing);
             Assignment(p.Assignment);
             text.Append('}');

OpenNest.Core/CNC/CuttingStrategy/CuttingParameters.cs

@@ -51,6 +51,32 @@ namespace OpenNest.CNC.CuttingStrategy
         /// </summary>
         public bool SupportTabs { get; set; }
 
+        /// <summary>
+        /// With <see cref="SupportTabs"/> on a plate that has no support bed, the narrowest part
+        /// width that is tabbed instead (see <see cref="TabsWithoutBedAt"/>).
+        /// </summary>
+        public double NoBedTabMinWidth { get; set; }
+
+        /// <summary>
+        /// With <see cref="SupportTabs"/> on a plate that has no support bed, the widest part
+        /// width that is tabbed instead; 0 turns the rule off, so nothing is tabbed without a bed.
+        /// </summary>
+        public double NoBedTabMaxWidth { get; set; }
+
+        /// <summary>Whether <see cref="NoBedTabMinWidth"/> to <see cref="NoBedTabMaxWidth"/> is a usable range.</summary>
+        public bool HasNoBedTabRange() =>
+            NoBedTabMaxWidth > 0 && double.IsFinite(NoBedTabMaxWidth)
+            && NoBedTabMinWidth >= 0 && NoBedTabMinWidth <= NoBedTabMaxWidth;
+
+        /// <summary>
+        /// Whether a part <paramref name="width"/> wide (the short side of its minimum-area
+        /// bounding rectangle) is tabbed when its plate has no support bed.
+        /// </summary>
+        public bool TabsWithoutBedAt(double width) =>
+            HasNoBedTabRange()
+            && width >= NoBedTabMinWidth - Math.Tolerance.Epsilon
+            && width <= NoBedTabMaxWidth + Math.Tolerance.Epsilon;
+
         public SequenceParameters Sequencing { get; set; } = new SequenceParameters();
         public AssignmentParameters Assignment { get; set; } = new AssignmentParameters();
     }

OpenNest.Core/Diagnostics/PartSupportReview.cs

@@ -10,10 +10,11 @@ using OpenNest.Support;
 namespace OpenNest.Diagnostics;
 
 /// <summary>
-/// Pre-post review of part support (docs/support-tabs.md). On a plate with a support bed, every
-/// part whose cutting parameters ask for support tabs and that the bed cannot hold level must be
+/// Pre-post review of part support (docs/support-tabs.md). Every part whose cutting parameters
+/// ask for support tabs and that needs one (<see cref="SupportTabSettings.Analyze"/>: its plate's
+/// support bed cannot hold it level or, without a bed, its width is in the no-bed range) must be
 /// cut with a tab that keeps it level, however its program was made (planned, placed by hand or
-/// locked). The tab is the gap the outside cut leaves between its end and its start. Reports
+/// locked); without a bed any tab will do. The tab is the gap the outside cut leaves between its end and its start. Reports
 /// only; a part whose material or program cannot be read is reported as not checked.
 /// </summary>
 internal static class PartSupportReview
@@ -21,19 +22,21 @@ internal static class PartSupportReview
     internal static void Add(Plate plate, int plateNumber, List<PostVerificationFinding> findings,
         CancellationToken token)
     {
-        if (plate.SupportBed is not { } bed)
-            return;
+        var bed = plate.SupportBed;
         for (var index = 0; index < plate.Parts.Count; index++)
         {
             token.ThrowIfCancellationRequested();
             var part = plate.Parts[index];
-            if (part?.BaseDrawing == null || part.BaseDrawing.IsCutOff
-                || (part.CuttingParameters ?? plate.CuttingParameters)?.SupportTabs != true)
+            var parameters = part?.CuttingParameters ?? plate.CuttingParameters;
+            if (part?.BaseDrawing == null || part.BaseDrawing.IsCutOff || parameters?.SupportTabs != true
+                || (bed == null && !parameters.HasNoBedTabRange()))
                 continue;
             var partNumber = index + 1;
             try
             {
-                var support = SupportAnalyzer.Analyze(bed, plate.Quadrant, part);
+                var support = SupportTabSettings.Analyze(parameters, bed, plate.Quadrant, SupportMaterial.FromPart(part));
+                if (support == null)
+                    continue;
                 if (!support.IsComplete)
                 {
                     findings.Add(new(PostVerificationKind.Incomplete, plateNumber, partNumber, null,
@@ -100,6 +103,14 @@ internal static class PartSupportReview
 
     private static string Message(PartSupport support, Vector? tab)
     {
+        // Without a bed any tab steadies the part, so the only failure is no tab at all.
+        if (!support.HasBed)
+            return FormattableString.Invariant(
+                    $"The part is {support.Width:0.####} wide, in the width range tabbed without a support bed, ")
+                + "and it has no tab; it may tip once cut free."
+                + (support.BestTabPoint is { } suggested
+                    ? FormattableString.Invariant($" Tab it near ({suggested.X:0.####}, {suggested.Y:0.####}).")
+                    : "");
         var held = support.Margin == double.NegativeInfinity
             ? "rests on no support contact"
             : support.Margin < 0

OpenNest.Core/Support/SupportAnalyzer.cs

@@ -58,20 +58,70 @@ namespace OpenNest.Support
             var contacts = bed.Contacts(material, quadrant, Vector.Zero);
 
             var corners = InsideCorners(material.Outline);
-            var samples = OutlineSamples(material.Outline)
+            var best = BestTabPoint(material.Outline, center, corners, insideCornerClearance,
+                point => MarginWith(center, hulls, point), out var bestMargin);
+
+            return new PartSupport(center, contacts, margin, bed.StabilityMargin, hulls, best, bestMargin,
+                corners, insideCornerClearance);
+        }
+
+        /// <summary>
+        /// A part on a plate with no support bed, tabbed for its <see cref="Width"/> instead
+        /// (<see cref="CNC.CuttingStrategy.CuttingParameters.TabsWithoutBedAt"/>). With no contacts
+        /// to judge by, a tab anywhere clear of inside corners is accepted; the best tab point is
+        /// the clear outline point nearest the line through the center of gravity across the
+        /// outline's long side, then the one farthest from an inside corner.
+        /// </summary>
+        /// <param name="insideCornerClearance">
+        /// How far a tab point keeps from an inside corner; 0 keeps it off the corner only.
+        /// </param>
+        public static PartSupport AnalyzeWithoutBed(SupportMaterial material, double insideCornerClearance = 0)
+        {
+            ArgumentNullException.ThrowIfNull(material);
+            if (!(insideCornerClearance >= 0) || double.IsInfinity(insideCornerClearance))
+                throw new ArgumentOutOfRangeException(nameof(insideCornerClearance));
+            if (!material.IsComplete)
+                return new PartSupport(material.Reason);
+            if (!material.TryGetCenterOfGravity(out var center, out _))
+                return new PartSupport("The part encloses no area.");
+
+            var corners = InsideCorners(material.Outline);
+            var best = BestTabPoint(material.Outline, center, corners, insideCornerClearance,
+                _ => double.PositiveInfinity, out _);
+            return new PartSupport(center, best, corners, insideCornerClearance, Width(material));
+        }
+
+        /// <summary>
+        /// The part's width: the short side of its outline's minimum-area bounding rectangle, or
+        /// NaN when its material could not be read.
+        /// </summary>
+        public static double Width(SupportMaterial material)
+        {
+            ArgumentNullException.ThrowIfNull(material);
+            if (!material.IsComplete || material.Outline.Count < 3)
+                return double.NaN;
+            var box = BoundingRectangle(material.Outline);
+            return System.Math.Min(box.Width, box.Height);
+        }
+
+        // The outline point a tab steadies the part most from, by `score`, clear of every inside
+        // corner where the outline allows it. A tab cannot lift the margin past the contacts' own
+        // hull edges, so a whole stretch of outline often ties; of those, the one nearest the line
+        // through the center across the outline's long side, then the one farthest from an inside
+        // corner, or the first.
+        private static Vector? BestTabPoint(IReadOnlyList<Vector> outline, Vector center, IReadOnlyList<Vector> corners,
+            double insideCornerClearance, Func<Vector, double> score, out double bestMargin)
+        {
+            var samples = OutlineSamples(outline)
                 .Select(point => (Point: point, Clear: Clearance(corners, point)))
                 .ToList();
-            // Clear of every inside corner where the outline allows it.
             var allowed = samples.Where(s => IsClear(s.Clear, insideCornerClearance)).ToList();
             if (allowed.Count > 0)
                 samples = allowed;
-            var scored = samples.Select(s => (s.Point, s.Clear, Margin: MarginWith(center, hulls, s.Point))).ToList();
+            var scored = samples.Select(s => (s.Point, s.Clear, Margin: score(s.Point))).ToList();
 
-            // A tab cannot lift the margin past the contacts' own hull edges, so a whole stretch
-            // of outline often ties; of those, the one nearest the line through the center across
-            // the outline's long side, then the one farthest from an inside corner, or the first.
-            var bestMargin = scored.Count == 0 ? double.NegativeInfinity : scored.Max(s => s.Margin);
-            var along = scored.Count == 0 ? Vector.Zero : LongSide(material.Outline);
+            bestMargin = scored.Count == 0 ? double.NegativeInfinity : scored.Max(s => s.Margin);
+            var along = scored.Count == 0 ? Vector.Zero : LongSide(outline);
             Vector? best = null;
             var bestOffset = double.PositiveInfinity;
             var bestClear = double.NegativeInfinity;
@@ -88,20 +138,21 @@ namespace OpenNest.Support
                     bestClear = sample.Clear;
                 }
             }
-
-            return new PartSupport(center, contacts, margin, bed.StabilityMargin, hulls, best, bestMargin,
-                corners, insideCornerClearance);
+            return best;
         }
 
         /// <summary>The unit direction of the longer side of the outline's minimum-area bounding rectangle.</summary>
         private static Vector LongSide(IReadOnlyList<Vector> outline)
         {
-            // The full angle range checks every hull edge.
-            var box = RotatingCalipers.MinimumBoundingRectangle(ConvexHull.Compute(outline.ToList()), 0, Math.Angle.TwoPI);
+            var box = BoundingRectangle(outline);
             var angle = box.Width >= box.Height ? box.Angle : box.Angle + Math.Angle.HalfPI;
             return new Vector(System.Math.Cos(angle), System.Math.Sin(angle));
         }
 
+        // The full angle range checks every hull edge.
+        private static BoundingRectangleResult BoundingRectangle(IReadOnlyList<Vector> outline) =>
+            RotatingCalipers.MinimumBoundingRectangle(ConvexHull.Compute(outline.ToList()), 0, Math.Angle.TwoPI);
+
         // A point `clear` from the nearest inside corner keeps `clearance` from it; with no
         // clearance it must still not be the corner.
         internal static bool IsClear(double clear, double clearance) =>
@@ -324,6 +375,31 @@ namespace OpenNest.Support
             InsideCornerClearance = insideCornerClearance;
         }
 
+        // A part on a plate with no bed, tabbed for its width: it rests on nothing modeled, and a
+        // tab anywhere clear of inside corners is as good as any other.
+        internal PartSupport(Vector centerOfGravity, Vector? bestTabPoint, IReadOnlyList<Vector> insideCorners,
+            double insideCornerClearance, double width)
+        {
+            HasBed = false;
+            CenterOfGravity = centerOfGravity;
+            Contacts = Array.Empty<Vector>();
+            BestTabPoint = bestTabPoint;
+            BestTabMargin = double.PositiveInfinity;
+            InsideCorners = insideCorners;
+            InsideCornerClearance = insideCornerClearance;
+            Width = width;
+        }
+
+        /// <summary>
+        /// False for a part on a plate with no support bed, tabbed for its <see cref="Width"/>
+        /// (<see cref="SupportAnalyzer.AnalyzeWithoutBed"/>): it has no contacts, never counts as
+        /// supported, and any tab clear of inside corners steadies it.
+        /// </summary>
+        public bool HasBed { get; } = true;
+
+        /// <summary>The part's width when analyzed without a bed (see <see cref="SupportAnalyzer.Width"/>); NaN otherwise.</summary>
+        public double Width { get; } = double.NaN;
+
         /// <summary>True when the part was analyzed; otherwise <see cref="Reason"/> says why not.</summary>
         public bool IsComplete => Reason == null;
 
@@ -363,7 +439,9 @@ namespace OpenNest.Support
 
         /// <summary>The worst margin with a tab holding the part at <paramref name="tab"/>.</summary>
         public double MarginWith(Vector tab) =>
-            IsComplete ? SupportAnalyzer.MarginWith(CenterOfGravity, hulls, tab) : double.NegativeInfinity;
+            !IsComplete ? double.NegativeInfinity
+            : !HasBed ? double.PositiveInfinity
+            : SupportAnalyzer.MarginWith(CenterOfGravity, hulls, tab);
 
         /// <summary>True when a tab at <paramref name="tab"/> holds the part level by the required margin.</summary>
         public bool IsSteadiedByTabAt(Vector tab) => IsComplete && Meets(MarginWith(tab));

OpenNest.Core/Support/SupportTabSettings.cs

@@ -5,26 +5,62 @@ using OpenNest.CNC.CuttingStrategy;
 namespace OpenNest.Support
 {
     /// <summary>
-    /// Cutting settings for a lead-in placed by hand under
-    /// <see cref="CuttingParameters.SupportTabs"/>: the tool cuts where it is clicked, so the
-    /// part is tabbed there when its plate's support bed cannot hold it level. Plan Cutting
-    /// chooses the tab point itself (docs/support-tabs.md).
+    /// Which parts <see cref="CuttingParameters.SupportTabs"/> tabs (docs/support-tabs.md): the
+    /// parts the plate's support bed cannot hold level or, on a plate with no bed, the parts
+    /// whose width is in the settings' no-bed range. Also the cutting settings for a lead-in
+    /// placed by hand: the tool cuts where it is clicked, so the part is tabbed there. Plan
+    /// Cutting chooses the tab point itself.
     /// </summary>
     public static class SupportTabSettings
     {
+        /// <summary>
+        /// The analysis that tabs a part, or null when support tabs are off or the part is
+        /// outside the rule: with a bed, the bed's analysis; without one, a no-bed analysis
+        /// (<see cref="SupportAnalyzer.AnalyzeWithoutBed"/>) of a part whose width is in
+        /// <see cref="CuttingParameters.TabsWithoutBedAt"/>'s range. The part needs a tab when
+        /// the result is complete and not supported; an incomplete result could not be read.
+        /// </summary>
+        /// <param name="insideCornerClearance">
+        /// How far a tab point keeps from an inside corner; 0 keeps it off the corner only.
+        /// </param>
+        public static PartSupport Analyze(CuttingParameters parameters, SupportBed bed, int quadrant,
+            SupportMaterial material, double insideCornerClearance = 0)
+        {
+            ArgumentNullException.ThrowIfNull(material);
+            if (parameters?.SupportTabs != true)
+                return null;
+            if (bed != null)
+                return SupportAnalyzer.Analyze(bed, quadrant, material, insideCornerClearance);
+            if (!parameters.HasNoBedTabRange())
+                return null;
+            if (!material.IsComplete)
+                return SupportAnalyzer.AnalyzeWithoutBed(material, insideCornerClearance);
+            return parameters.TabsWithoutBedAt(SupportAnalyzer.Width(material))
+                ? SupportAnalyzer.AnalyzeWithoutBed(material, insideCornerClearance)
+                : null;
+        }
+
+        /// <summary>
+        /// Whether support tabs are on but can tab nothing: the plate has no support bed and the
+        /// settings set no no-bed width range.
+        /// </summary>
+        public static bool SkipsWithoutBed(CuttingParameters parameters, SupportBed bed) =>
+            parameters?.SupportTabs == true && bed == null && !parameters.HasNoBedTabRange();
+
         /// <summary>
         /// <paramref name="parameters"/> itself, or a copy with tabs enabled when support tabs are
-        /// on, the plate has a support bed, a tab size is set and the bed cannot hold
-        /// <paramref name="part"/> level. The caller's settings are never changed.
+        /// on, a tab size is set and <paramref name="part"/> needs a tab (see <see cref="Analyze"/>).
+        /// The caller's settings are never changed.
         /// </summary>
         public static CuttingParameters ForManualLeadIn(CuttingParameters parameters, Plate plate, Part part)
         {
             ArgumentNullException.ThrowIfNull(parameters);
             if (!parameters.SupportTabs || parameters.TabsEnabled || parameters.TabConfig == null
-                || plate?.SupportBed == null || part == null)
+                || plate == null || part == null
+                || (plate.SupportBed == null && !parameters.HasNoBedTabRange()))
                 return parameters;
-            var support = SupportAnalyzer.Analyze(plate.SupportBed, plate.Quadrant, part);
-            if (!support.IsComplete || support.IsSupported)
+            var support = Analyze(parameters, plate.SupportBed, plate.Quadrant, SupportMaterial.FromPart(part));
+            if (support is not { IsComplete: true, IsSupported: false })
                 return parameters;
             var tabbed = OwnedCuttingParameters.Copy(parameters);
             tabbed.TabsEnabled = true;