From 630d514b0ec261168ed54c329f7daa0136b1935a Mon Sep 17 00:00:00 2001
From: AJ Isaacs <ajisaacs27@gmail.com>
Date: Mon, 21 Sep 2026 11:07:45 -0400
Subject: [PATCH] fix(engine): don't drop the topmost part when no other
 drawing is waiting

RemnantFiller removes the topmost placed part to keep a clean rectangular
obstacle for the next drawing, but the envelope then walls that slot off,
so the part was lost for nothing (4 squares on a 9x9 plate became 3).
Only remove it while another drawing still has demand.

Fixes the mixed-stock NestRunner tests.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
---
 OpenNest.Engine/Fill/RemnantFiller.cs      | 22 +++++++++++++++++-
 OpenNest.Tests/Fill/RemnantFillerTests2.cs | 26 ++++++++++++++++++++++
 2 files changed, 47 insertions(+), 1 deletion(-)

diff --git a/OpenNest.Engine/Fill/RemnantFiller.cs b/OpenNest.Engine/Fill/RemnantFiller.cs
index ddf9dee..22b18aa 100644
--- a/OpenNest.Engine/Fill/RemnantFiller.cs
+++ b/OpenNest.Engine/Fill/RemnantFiller.cs
@@ -114,7 +114,10 @@ namespace OpenNest.Engine.Fill
                 // rectangular obstacle boundary. Without this, gaps between
                 // individual bounding boxes cause the next drawing to fill
                 // into inter-row spaces, producing an interleaved layout.
-                if (placed.Count > 2)
+                // Only worthwhile while another drawing is still waiting for
+                // space; otherwise the removed part's slot is walled off by the
+                // envelope below and the part is lost for nothing.
+                if (placed.Count > 2 && HasOtherDemand(items, item, localQty))
                     RemoveTopmostPart(placed);
 
                 allParts.AddRange(placed);
@@ -132,6 +135,23 @@ namespace OpenNest.Engine.Fill
             return false;
         }
 
+        private static bool HasOtherDemand(
+            List<NestItem> items,
+            NestItem current,
+            Dictionary<Drawing, int> localQty
+        )
+        {
+            foreach (var other in items)
+            {
+                if (ReferenceEquals(other.Drawing, current.Drawing))
+                    continue;
+                if (localQty[other.Drawing] > 0)
+                    return true;
+            }
+
+            return false;
+        }
+
         private static void RemoveTopmostPart(List<Part> parts)
         {
             var topIdx = 0;
diff --git a/OpenNest.Tests/Fill/RemnantFillerTests2.cs b/OpenNest.Tests/Fill/RemnantFillerTests2.cs
index 2e37714..498570e 100644
--- a/OpenNest.Tests/Fill/RemnantFillerTests2.cs
+++ b/OpenNest.Tests/Fill/RemnantFillerTests2.cs
@@ -103,4 +103,30 @@ public class RemnantFillerTests2
         // Should not throw, returns whatever was placed
         Assert.NotNull(result);
     }
+
+    [Fact]
+    public void FillItems_SingleDrawing_KeepsEveryPlacedPart()
+    {
+        // With no other drawing waiting for space there is nothing to keep clear, so a full
+        // grid fill must not lose its topmost part.
+        var workArea = new Box(0, 0, 100, 100);
+        var filler = new RemnantFiller(workArea, 0);
+        var items = new List<NestItem>
+        {
+            new NestItem { Drawing = MakeSquareDrawing(10), Quantity = 4 },
+        };
+
+        Func<NestItem, Box, List<Part>> fillFunc = (ni, b) =>
+            new List<Part>
+            {
+                TestHelpers.MakePartAt(0, 0, 10),
+                TestHelpers.MakePartAt(10, 0, 10),
+                TestHelpers.MakePartAt(0, 10, 10),
+                TestHelpers.MakePartAt(10, 10, 10),
+            };
+
+        var placed = filler.FillItems(items, fillFunc);
+
+        Assert.Equal(4, placed.Count);
+    }
 }