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fix: ShapeProfile selects perimeter by largest bounding box area

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Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
This commit is contained in:
AJ Isaacs
2026-03-22 22:29:00 -04:00
parent f79df4d426
commit 48b4849a88
2 changed files with 360 additions and 2 deletions
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7
OpenNest.Core/Geometry/ShapeProfile.cs
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@@ -21,9 +21,12 @@ namespace OpenNest.Geometry
Perimeter = shapes[0];
Cutouts = new List<Shape>();
for (int i = 1; i < shapes.Count; i++)
for (var i = 1; i < shapes.Count; i++)
{
if (shapes[i].Left < Perimeter.Left)
var bb = shapes[i].BoundingBox;
var perimBB = Perimeter.BoundingBox;
if (bb.Width * bb.Length > perimBB.Width * perimBB.Length)
{
Cutouts.Add(Perimeter);
Perimeter = shapes[i];

355
OpenNest.Tests/CutOffGeometryTests.cs Normal file
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@@ -0,0 +1,355 @@
using System.Collections.Generic;
using System.Linq;
using OpenNest.CNC;
using OpenNest.Geometry;
namespace OpenNest.Tests;
public class CutOffGeometryTests
{
private static readonly CutOffSettings ZeroClearance = new() { PartClearance = 0.0 };
private static Program MakeSquare(double size)
{
var pgm = new Program();
pgm.Codes.Add(new RapidMove(new Vector(0, 0)));
pgm.Codes.Add(new LinearMove(new Vector(size, 0)));
pgm.Codes.Add(new LinearMove(new Vector(size, size)));
pgm.Codes.Add(new LinearMove(new Vector(0, size)));
pgm.Codes.Add(new LinearMove(new Vector(0, 0)));
return pgm;
}
private static Program MakeCircle(double radius)
{
// Rapid to (radius, 0) relative to center at (0, 0),
// then full-circle arc back to same point.
var pgm = new Program();
pgm.Codes.Add(new RapidMove(new Vector(radius, 0)));
pgm.Codes.Add(new ArcMove(new Vector(radius, 0), new Vector(0, 0)));
return pgm;
}
private static Program MakeDiamond(double halfSize)
{
// Diamond: points at (half,0), (2*half,half), (half,2*half), (0,half)
var pgm = new Program();
pgm.Codes.Add(new RapidMove(new Vector(halfSize, 0)));
pgm.Codes.Add(new LinearMove(new Vector(halfSize * 2, halfSize)));
pgm.Codes.Add(new LinearMove(new Vector(halfSize, halfSize * 2)));
pgm.Codes.Add(new LinearMove(new Vector(0, halfSize)));
pgm.Codes.Add(new LinearMove(new Vector(halfSize, 0)));
return pgm;
}
private static Program MakeTriangle(double width, double height)
{
// Right triangle: (0,0) -> (width,0) -> (0,height) -> (0,0)
var pgm = new Program();
pgm.Codes.Add(new RapidMove(new Vector(0, 0)));
pgm.Codes.Add(new LinearMove(new Vector(width, 0)));
pgm.Codes.Add(new LinearMove(new Vector(0, height)));
pgm.Codes.Add(new LinearMove(new Vector(0, 0)));
return pgm;
}
[Fact]
public void Square_GeometryExclusionMatchesBoundingBox()
{
// For a square, geometry and BB should produce the same exclusion.
var drawing = new Drawing("sq", MakeSquare(20));
var plate = new Plate(100, 100);
var part = Part.CreateAtOrigin(drawing);
part.Location = new Vector(10, 10);
plate.Parts.Add(part);
// Vertical cut at X=20 (through the middle of the square).
// BB exclusion Y = [10, 30]. Geometry should give the same.
var cutoff = new CutOff(new Vector(20, 0), CutOffAxis.Vertical);
cutoff.Regenerate(plate, ZeroClearance);
var codes = cutoff.Drawing.Program.Codes;
// Two segments: before and after the square → 4 codes
Assert.Equal(4, codes.Count);
}
[Fact]
public void Circle_GeometryExclusionNarrowerThanBoundingBox()
{
// Circle radius=10, center at (10,10) after placement.
// BB = (0,0,20,20). Vertical cut at X=2 clips the circle edge.
// BB would exclude full Y=[0,20].
// Geometry: at X=2, the chord is much narrower.
var drawing = new Drawing("circ", MakeCircle(10));
var plate = new Plate(100, 100);
var part = Part.CreateAtOrigin(drawing);
part.Location = new Vector(0, 0);
plate.Parts.Add(part);
var cache = CutOff.BuildPerimeterCache(plate);
// Cut at X=2: inside the BB but near the edge of the circle.
var cutoff = new CutOff(new Vector(2, 0), CutOffAxis.Vertical);
cutoff.Regenerate(plate, ZeroClearance, cache);
// The circle chord at X=2 from center (10,0) is much shorter than 20.
// With geometry, we get a tighter exclusion, so the segments should
// cover more of the plate than with BB.
var segments = cutoff.Drawing.Program.Codes.OfType<LinearMove>().ToList();
Assert.True(segments.Count >= 1);
// Total cut length should be greater than 80 (BB would give 100-20=80)
var totalCutLength = 0.0;
for (var i = 0; i < cutoff.Drawing.Program.Codes.Count - 1; i += 2)
{
if (cutoff.Drawing.Program.Codes[i] is RapidMove rapid &&
cutoff.Drawing.Program.Codes[i + 1] is LinearMove linear)
{
totalCutLength += System.Math.Abs(rapid.EndPoint.Y - linear.EndPoint.Y);
}
}
Assert.True(totalCutLength > 80, $"Geometry should give more cut length than BB. Got {totalCutLength:F2}");
}
[Fact]
public void Diamond_GeometryExclusionNarrowerThanBoundingBox()
{
// Diamond half=10 → points at (10,0), (20,10), (10,20), (0,10).
// BB = (0,0,20,20).
// Vertical cut at X=5: BB excludes Y=[0,20].
// Diamond edge at X=5: intersects at Y=5 and Y=15 → exclusion [5,15].
var drawing = new Drawing("dia", MakeDiamond(10));
var plate = new Plate(100, 100);
var part = Part.CreateAtOrigin(drawing);
part.Location = new Vector(0, 0);
plate.Parts.Add(part);
var cache = CutOff.BuildPerimeterCache(plate);
var cutoff = new CutOff(new Vector(5, 0), CutOffAxis.Vertical);
cutoff.Regenerate(plate, ZeroClearance, cache);
var totalCutLength = 0.0;
for (var i = 0; i < cutoff.Drawing.Program.Codes.Count - 1; i += 2)
{
if (cutoff.Drawing.Program.Codes[i] is RapidMove rapid &&
cutoff.Drawing.Program.Codes[i + 1] is LinearMove linear)
{
totalCutLength += System.Math.Abs(rapid.EndPoint.Y - linear.EndPoint.Y);
}
}
// BB would exclude full 20 → cut length = 80.
// Geometry excludes only 10 → cut length = 90.
Assert.True(totalCutLength > 85, $"Diamond geometry should give more cut than BB. Got {totalCutLength:F2}");
}
[Fact]
public void Triangle_AsymmetricExclusion()
{
// Right triangle: (0,0)→(30,0)→(0,30)→(0,0) placed at (10,10).
// Vertical cut at X=20 (10 into the triangle from left).
// The hypotenuse from (40,10) to (10,40): at X=20, Y = 30.
// So geometry exclusion should be roughly [10, 30], not [10, 40] like BB.
var drawing = new Drawing("tri", MakeTriangle(30, 30));
var plate = new Plate(100, 100);
var part = Part.CreateAtOrigin(drawing);
part.Location = new Vector(10, 10);
plate.Parts.Add(part);
var cache = CutOff.BuildPerimeterCache(plate);
var cutoff = new CutOff(new Vector(20, 0), CutOffAxis.Vertical);
cutoff.Regenerate(plate, ZeroClearance, cache);
var totalCutLength = 0.0;
for (var i = 0; i < cutoff.Drawing.Program.Codes.Count - 1; i += 2)
{
if (cutoff.Drawing.Program.Codes[i] is RapidMove rapid &&
cutoff.Drawing.Program.Codes[i + 1] is LinearMove linear)
{
totalCutLength += System.Math.Abs(rapid.EndPoint.Y - linear.EndPoint.Y);
}
}
// BB would exclude [10,40] = 30 → cut = 70.
// Geometry excludes [10,30] = 20 → cut = 80.
Assert.True(totalCutLength > 75, $"Triangle geometry should give more cut than BB. Got {totalCutLength:F2}");
}
[Fact]
public void CutLineMissesPart_NoExclusion()
{
var drawing = new Drawing("sq", MakeSquare(10));
var plate = new Plate(100, 100);
var part = Part.CreateAtOrigin(drawing);
part.Location = new Vector(50, 50);
plate.Parts.Add(part);
// Vertical cut at X=5: well outside the part at X=[50,60].
var cutoff = new CutOff(new Vector(5, 0), CutOffAxis.Vertical);
cutoff.Regenerate(plate, ZeroClearance);
// Single full-length segment → 2 codes
Assert.Equal(2, cutoff.Drawing.Program.Codes.Count);
}
[Fact]
public void HorizontalCut_Circle_UsesGeometry()
{
var drawing = new Drawing("circ", MakeCircle(10));
var plate = new Plate(100, 100);
var part = Part.CreateAtOrigin(drawing);
part.Location = new Vector(0, 0);
plate.Parts.Add(part);
var cache = CutOff.BuildPerimeterCache(plate);
// Horizontal cut at Y=2: near the edge of the circle.
var cutoff = new CutOff(new Vector(0, 2), CutOffAxis.Horizontal);
cutoff.Regenerate(plate, ZeroClearance, cache);
var totalCutLength = 0.0;
for (var i = 0; i < cutoff.Drawing.Program.Codes.Count - 1; i += 2)
{
if (cutoff.Drawing.Program.Codes[i] is RapidMove rapid &&
cutoff.Drawing.Program.Codes[i + 1] is LinearMove linear)
{
totalCutLength += System.Math.Abs(rapid.EndPoint.X - linear.EndPoint.X);
}
}
// BB would exclude X=[0,20] → cut = 80.
// Circle chord at Y=2 is much shorter → cut > 80.
Assert.True(totalCutLength > 80, $"Circle horizontal cut should use geometry. Got {totalCutLength:F2}");
}
[Fact]
public void Clearance_ExpandsGeometryExclusion()
{
var drawing = new Drawing("sq", MakeSquare(20));
var plate = new Plate(100, 100);
var part = Part.CreateAtOrigin(drawing);
part.Location = new Vector(10, 10);
plate.Parts.Add(part);
var settings = new CutOffSettings { PartClearance = 5.0 };
var cache = CutOff.BuildPerimeterCache(plate);
var cutoff = new CutOff(new Vector(20, 0), CutOffAxis.Vertical);
cutoff.Regenerate(plate, settings, cache);
// Square at Y=[10,30]. With 5 clearance → exclusion [5,35].
// Segments: [0,5] and [35,100] → 4 codes.
Assert.Equal(4, cutoff.Drawing.Program.Codes.Count);
}
[Fact]
public void BuildPerimeterCache_ReturnsOneEntryPerPart()
{
var plate = new Plate(100, 100);
plate.Parts.Add(new Part(new Drawing("a", MakeSquare(10))));
plate.Parts.Add(new Part(new Drawing("b", MakeCircle(5))));
plate.Parts.Add(new Part(new Drawing("c", MakeDiamond(8))));
var cache = CutOff.BuildPerimeterCache(plate);
Assert.Equal(3, cache.Count);
}
[Fact]
public void BuildPerimeterCache_SkipsCutOffParts()
{
var plate = new Plate(100, 100);
plate.Parts.Add(new Part(new Drawing("real", MakeSquare(10))));
plate.Parts.Add(new Part(new Drawing("cutoff", new Program()) { IsCutOff = true }));
var cache = CutOff.BuildPerimeterCache(plate);
Assert.Single(cache);
}
[Fact]
public void BuildPerimeterCache_NullForOpenContour()
{
// Open contour: line that doesn't close
var pgm = new Program();
pgm.Codes.Add(new RapidMove(new Vector(0, 0)));
pgm.Codes.Add(new LinearMove(new Vector(10, 0)));
pgm.Codes.Add(new LinearMove(new Vector(10, 10)));
var plate = new Plate(100, 100);
plate.Parts.Add(new Part(new Drawing("open", pgm)));
var cache = CutOff.BuildPerimeterCache(plate);
Assert.Single(cache);
Assert.Null(cache[0]);
}
[Fact]
public void NullCache_FallsBackToBoundingBox()
{
// Without a cache, should still work (using BB fallback).
var drawing = new Drawing("sq", MakeSquare(20));
var plate = new Plate(100, 100);
var part = Part.CreateAtOrigin(drawing);
part.Location = new Vector(10, 10);
plate.Parts.Add(part);
var cutoff = new CutOff(new Vector(20, 0), CutOffAxis.Vertical);
cutoff.Regenerate(plate, ZeroClearance, null);
Assert.True(cutoff.Drawing.Program.Codes.Count > 0);
}
[Fact]
public void MultipleParts_IndependentExclusions()
{
var plate = new Plate(100, 100);
var sq1 = new Drawing("sq1", MakeSquare(10));
var p1 = Part.CreateAtOrigin(sq1);
p1.Location = new Vector(10, 10);
plate.Parts.Add(p1);
var sq2 = new Drawing("sq2", MakeSquare(10));
var p2 = Part.CreateAtOrigin(sq2);
p2.Location = new Vector(10, 50);
plate.Parts.Add(p2);
// Vertical cut at X=15 crosses both parts.
var cutoff = new CutOff(new Vector(15, 0), CutOffAxis.Vertical);
cutoff.Regenerate(plate, ZeroClearance);
// 3 segments: before p1, between p1 and p2, after p2 → 6 codes
Assert.Equal(6, cutoff.Drawing.Program.Codes.Count);
}
[Fact]
public void ShapeProfile_SelectsLargestShapeAsPerimeter()
{
// Outer square: (5,0)→(25,0)→(25,20)→(5,20)→(5,0)
// Inner cutout: (0,5)→(10,5)→(10,15)→(0,15)→(0,5)
// The cutout has Left=0, perimeter has Left=5.
// Old heuristic would pick the cutout as perimeter.
var outer = new Shape();
outer.Entities.Add(new Line(new Vector(5, 0), new Vector(25, 0)));
outer.Entities.Add(new Line(new Vector(25, 0), new Vector(25, 20)));
outer.Entities.Add(new Line(new Vector(25, 20), new Vector(5, 20)));
outer.Entities.Add(new Line(new Vector(5, 20), new Vector(5, 0)));
var inner = new Shape();
inner.Entities.Add(new Line(new Vector(0, 5), new Vector(10, 5)));
inner.Entities.Add(new Line(new Vector(10, 5), new Vector(10, 15)));
inner.Entities.Add(new Line(new Vector(10, 15), new Vector(0, 15)));
inner.Entities.Add(new Line(new Vector(0, 15), new Vector(0, 5)));
// Combine all entities (simulating what ShapeBuilder.GetShapes would produce)
var entities = new List<Entity>();
entities.AddRange(inner.Entities); // inner first — worst case for old heuristic
entities.AddRange(outer.Entities);
var profile = new ShapeProfile(entities);
// Perimeter should be the outer (larger) shape
var bb = profile.Perimeter.BoundingBox;
Assert.Equal(20.0, bb.Width, 1);
Assert.Equal(20.0, bb.Length, 1);
}
}