fix(geometry): correct overlap detection for real-world CNC shapes
Part.Intersects has been silently non-functional everywhere it's used. Shape.ToPolygon()/ToPolygonWithTolerance() never called UpdateBounds(), so every freshly-built polygon kept Entity's constructor-default zero-size bounding box regardless of its actual vertices. Collision.Check's first step is a bounding-box pre-filter, and a zero-size box can never overlap anything, so it always short-circuited to "no overlap" no matter what the real geometry looked like. That masked a second bug: Part.Intersects built its polygons via the unconditional 1000-segments-per-arc ToPolygon() default instead of an adaptive tolerance. For parts with several small fillets/holes this produced tens of thousands of vertices, making the now-correct bbox check fall through into a triangulation/clip step too slow to return in practice. Switched to ToPolygonWithTolerance at a named tolerance matching PartGeometry's existing convention. PairEvaluator's own Keep/overlap check had a third, independent bug: it used Shape.Intersects (edge-crossing detection only) at a coarse 0.01 chord tolerance, which misses containment-style overlaps and can polygonize rounded corners coarsely enough to hide a genuine sliver overlap. Switched to Collision.HasOverlap (full polygon clip, handles containment) at a tighter dedicated tolerance. Verified against a real nest file: PairFiller was tiling a BestFit pair that PairEvaluator had incorrectly marked Keep=true, producing visibly overlapping parts on the plate that no downstream overlap check ever caught. Known follow-up: OpenNest.Tests.BestFit.BestFitOverlapTests.KeptPairs_NoOverlap still fails on 3/1082 synthetic candidates that overlap by a sub-0.001 sliver right at a rounded-corner tangent point — a separate, much smaller precision edge case in PairEvaluator's raw (pre-transform) coordinate frame, not a regression from this change.
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@@ -13,6 +13,15 @@ namespace OpenNest.Engine.BestFit
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{
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private const double ChordTolerance = 0.01;
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/// <summary>
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/// Tighter chord tolerance for the overlap check only. Rounded-corner arcs
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/// polygonized at the coarser <see cref="ChordTolerance"/> can "cut the corner"
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/// enough to hide a genuine but tiny sliver overlap between two candidates —
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/// this needs to match the precision Part.Intersects uses elsewhere so BestFit's
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/// Keep decision agrees with the same overlap check callers rely on downstream.
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/// </summary>
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private const double OverlapChordTolerance = 0.001;
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public List<BestFitResult> EvaluateAll(List<PairCandidate> candidates)
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{
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if (candidates.Count == 0)
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@@ -49,10 +58,18 @@ namespace OpenNest.Engine.BestFit
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part2.Location = candidate.Part2Offset;
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part2.UpdateBounds();
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// Overlap check — perimeter vs perimeter
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// Overlap check — perimeter vs perimeter. Uses Collision.HasOverlap (full polygon
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// clip) rather than Shape.Intersects (edge-crossing only), which misses containment-
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// style overlaps where one perimeter's boundary never crosses the other's.
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var shape1 = GetPerimeterShape(part1);
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var shape2 = GetPerimeterShape(part2);
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var overlaps = shape1 != null && shape2 != null && shape1.Intersects(shape2, out _);
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var overlaps =
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shape1 != null
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&& shape2 != null
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&& Collision.HasOverlap(
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shape1.ToPolygonWithTolerance(OverlapChordTolerance),
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shape2.ToPolygonWithTolerance(OverlapChordTolerance)
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);
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// Convex hull vertices from perimeter polygons only
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var allPoints = GetPartVertices(part1);
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