fix(splitter): preserve disconnected strips and trim cuts around cutouts
Splits that cross an interior cutout previously merged physically disconnected strips into one drawing and drew cut lines through the hole. The region boundary now spans full feature-edge extents (trimmed against cutout polygons) and line entities are Liang-Barsky clipped, so multi-split edges work. Arcs are properly clipped at region boundaries via iterative split-at-intersection so circles that straddle a split contribute to both sides. AssemblePieces groups a region's entities into connected closed loops and nests holes by bbox-pre-check + vertex-in-polygon containment, so one region can emit multiple drawings when a cutout fully spans it. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
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@@ -384,6 +384,161 @@ public class DrawingSplitterTests
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}
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}
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[Fact]
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public void Split_RectangleWithSpanningSlot_ProducesDisconnectedStrips()
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{
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// 255x55 outer rectangle with a 235x35 interior slot centered at (10,10)-(245,45).
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// 4 vertical splits at x = 55, 110, 165, 220.
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//
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// Expected: regions R2/R3/R4 are entirely "over" the slot horizontally, so the
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// surviving material in each is two physically disjoint strips (upper + lower).
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// R1 and R5 each have a solid edge that connects the top and bottom strips, so
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// they remain single (notched) pieces.
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//
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// Total output drawings: 1 (R1) + 2 (R2) + 2 (R3) + 2 (R4) + 1 (R5) = 8.
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var outerEntities = new List<Entity>
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{
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new Line(new Vector(0, 0), new Vector(255, 0)),
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new Line(new Vector(255, 0), new Vector(255, 55)),
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new Line(new Vector(255, 55), new Vector(0, 55)),
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new Line(new Vector(0, 55), new Vector(0, 0))
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};
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var slotEntities = new List<Entity>
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{
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new Line(new Vector(10, 10), new Vector(245, 10)),
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new Line(new Vector(245, 10), new Vector(245, 45)),
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new Line(new Vector(245, 45), new Vector(10, 45)),
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new Line(new Vector(10, 45), new Vector(10, 10))
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};
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var allEntities = new List<Entity>();
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allEntities.AddRange(outerEntities);
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allEntities.AddRange(slotEntities);
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var drawing = new Drawing("SLOT", ConvertGeometry.ToProgram(allEntities));
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var originalArea = drawing.Area;
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var splitLines = new List<SplitLine>
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{
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new SplitLine(55.0, CutOffAxis.Vertical),
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new SplitLine(110.0, CutOffAxis.Vertical),
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new SplitLine(165.0, CutOffAxis.Vertical),
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new SplitLine(220.0, CutOffAxis.Vertical)
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};
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var results = DrawingSplitter.Split(drawing, splitLines, new SplitParameters { Type = SplitType.Straight });
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// R1 (0..55) → 1 notched piece, height 55
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// R2 (55..110) → upper strip + lower strip, each height 10
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// R3 (110..165)→ upper strip + lower strip, each height 10
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// R4 (165..220)→ upper strip + lower strip, each height 10
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// R5 (220..255)→ 1 notched piece, height 55
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Assert.Equal(8, results.Count);
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// Area preservation: sum of all output areas equals (outer − slot).
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var totalArea = results.Sum(d => d.Area);
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Assert.Equal(originalArea, totalArea, 1);
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// Box.Length = X-extent, Box.Width = Y-extent.
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// Exactly 6 strips (Y-extent ~10mm) from the three middle regions, and
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// exactly 2 notched pieces (Y-extent 55mm) from R1 and R5.
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var strips = results
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.Where(d => System.Math.Abs(d.Program.BoundingBox().Width - 10.0) < 0.5)
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.ToList();
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var notched = results
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.Where(d => System.Math.Abs(d.Program.BoundingBox().Width - 55.0) < 0.5)
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.ToList();
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Assert.Equal(6, strips.Count);
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Assert.Equal(2, notched.Count);
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// Each piece should form a closed perimeter (no dangling edges, no gaps).
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foreach (var piece in results)
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{
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var entities = ConvertProgram.ToGeometry(piece.Program)
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.Where(e => e.Layer != SpecialLayers.Rapid).ToList();
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Assert.True(entities.Count >= 3, $"{piece.Name} must have at least 3 edges");
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for (var i = 0; i < entities.Count; i++)
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{
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var end = GetEndPoint(entities[i]);
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var nextStart = GetStartPoint(entities[(i + 1) % entities.Count]);
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var gap = end.DistanceTo(nextStart);
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Assert.True(gap < 0.01,
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$"{piece.Name} gap of {gap:F4} between edge {i} end and edge {(i + 1) % entities.Count} start");
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}
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}
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}
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[Fact]
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public void Split_DxfFile_WithSpanningSlot_HasNoCutLinesThroughCutout()
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{
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// Real DXF regression: 255x55 plate with a centered slot cutout, split into
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// five columns. Exercises the same path as the synthetic
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// Split_RectangleWithSpanningSlot_ProducesDisconnectedStrips test but through
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// the full DXF import pipeline.
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var path = Path.Combine(AppContext.BaseDirectory, "Splitting", "TestData", "split_test.dxf");
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Assert.True(File.Exists(path), $"Test DXF not found: {path}");
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var imported = OpenNest.IO.Dxf.Import(path);
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var profile = new OpenNest.Geometry.ShapeProfile(imported.Entities);
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// Normalize to origin so the split line positions are predictable.
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var bb = profile.Perimeter.BoundingBox;
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var offsetX = -bb.X;
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var offsetY = -bb.Y;
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foreach (var e in profile.Perimeter.Entities) e.Offset(offsetX, offsetY);
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foreach (var cutout in profile.Cutouts)
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foreach (var e in cutout.Entities) e.Offset(offsetX, offsetY);
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var allEntities = new List<Entity>();
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allEntities.AddRange(profile.Perimeter.Entities);
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foreach (var cutout in profile.Cutouts) allEntities.AddRange(cutout.Entities);
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var drawing = new Drawing("SPLITTEST", ConvertGeometry.ToProgram(allEntities));
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var originalArea = drawing.Area;
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// Part is ~255x55 with an interior slot. Split into 5 columns (55mm each).
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var splitLines = new List<SplitLine>
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{
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new SplitLine(55.0, CutOffAxis.Vertical),
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new SplitLine(110.0, CutOffAxis.Vertical),
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new SplitLine(165.0, CutOffAxis.Vertical),
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new SplitLine(220.0, CutOffAxis.Vertical)
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};
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var results = DrawingSplitter.Split(drawing, splitLines, new SplitParameters { Type = SplitType.Straight });
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// Area must be preserved within tolerance (floating-point coords in the DXF).
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var totalArea = results.Sum(d => d.Area);
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Assert.Equal(originalArea, totalArea, 0);
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// At least one region must yield more than one physical strip — that's the
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// whole point of the fix: a cutout that spans a region disconnects it.
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Assert.True(results.Count > splitLines.Count + 1,
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$"Expected more than {splitLines.Count + 1} pieces (some regions split into strips), got {results.Count}");
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// Every output drawing must resolve into fully-closed shapes (outer loop
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// and any hole loops), with no dangling geometry. A piece that contains
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// a cutout will have its entities span more than one connected loop.
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foreach (var piece in results)
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{
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var entities = ConvertProgram.ToGeometry(piece.Program)
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.Where(e => e.Layer != SpecialLayers.Rapid).ToList();
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Assert.True(entities.Count >= 3, $"{piece.Name} has only {entities.Count} entities");
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var shapes = OpenNest.Geometry.ShapeBuilder.GetShapes(entities);
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Assert.NotEmpty(shapes);
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foreach (var shape in shapes)
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{
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Assert.True(shape.IsClosed(),
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$"{piece.Name} contains an open chain of {shape.Entities.Count} entities");
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}
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}
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}
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private static Vector GetStartPoint(Entity entity)
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{
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return entity switch
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