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fix: add overlap detection safety net for pair tiling

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Shape.OffsetOutward produces inward offsets for certain rotated polygons,
causing geometry-aware copy distances to be too small and placing
overlapping parts. Root cause is in the offset winding direction
detection — this commit adds safety nets while that is investigated.

- FillLinear.FillGrid: detect bbox overlaps after geometry-aware tiling,
  fall back to bbox-based spacing when overlaps found
- FillExtents.RepeatColumns: detect overlaps after Compactor computes
  copy distance, fall back to columnWidth + spacing
- PairFiller/StripeFiller remnant fills: use FillLinear directly instead
  of spawning full engine pipeline (avoids strategies with the bug)
- Add PairOverlapDiagnosticTests reproducing the issue
- MCP config: use shadow-copy wrapper for dev hot-reload

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
This commit is contained in:
AJ Isaacs
2026-03-27 23:52:50 -04:00
parent d7eb3ebd7a
commit 80e8693da3
6 changed files with 361 additions and 22 deletions
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16
OpenNest.Engine/Fill/FillExtents.cs
View File

@@ -3,6 +3,7 @@ using OpenNest.Math;
using System;
using System.Collections.Generic;
using System.Diagnostics;
using System.Linq;
using System.Threading;
namespace OpenNest.Engine.Fill
@@ -349,6 +350,21 @@ namespace OpenNest.Engine.Fill
if (copyDistance <= Tolerance.Epsilon)
copyDistance = columnWidth + partSpacing;
// Safety: if the compacted test column overlaps the original column,
// fall back to bbox-based spacing.
var probe = new List<Part>(column);
probe.AddRange(testColumn.Where(IsWithinWorkArea));
if (HasOverlappingParts(probe))
{
Debug.WriteLine($"[FillExtents] Compacted column overlaps, falling back to bbox spacing");
copyDistance = columnWidth + partSpacing;
// Rebuild test column at safe distance.
testColumn.Clear();
foreach (var part in column)
testColumn.Add(part.CloneAtOffset(new Vector(copyDistance, 0)));
}
Debug.WriteLine($"[FillExtents] Column copy distance: {copyDistance:F2} (bbox width: {columnWidth:F2}, spacing: {partSpacing:F2})");
// Build all columns.

74
OpenNest.Engine/Fill/FillLinear.cs
View File

@@ -287,6 +287,65 @@ namespace OpenNest.Engine.Fill
return result;
}
/// <summary>
/// Fallback tiling using bounding-box spacing when geometry-aware tiling
/// produces overlapping parts.
/// </summary>
private List<Part> TilePatternBbox(Pattern basePattern, NestDirection direction)
{
var copyDistance = GetDimension(basePattern.BoundingBox, direction) + PartSpacing;
if (copyDistance <= 0)
return new List<Part>();
var dim = GetDimension(basePattern.BoundingBox, direction);
var start = GetStart(basePattern.BoundingBox, direction);
var limit = GetLimit(direction);
var result = new List<Part>();
var count = 1;
while (true)
{
var nextPos = start + copyDistance * count;
if (nextPos + dim > limit + Tolerance.Epsilon)
break;
var offset = MakeOffset(direction, copyDistance * count);
foreach (var part in basePattern.Parts)
result.Add(part.CloneAtOffset(offset));
count++;
}
return result;
}
private static bool HasOverlappingParts(List<Part> parts)
{
for (var i = 0; i < parts.Count; i++)
{
var b1 = parts[i].BoundingBox;
for (var j = i + 1; j < parts.Count; j++)
{
var b2 = parts[j].BoundingBox;
var overlapX = System.Math.Min(b1.Right, b2.Right)
- System.Math.Max(b1.Left, b2.Left);
var overlapY = System.Math.Min(b1.Top, b2.Top)
- System.Math.Max(b1.Bottom, b2.Bottom);
if (overlapX > Tolerance.Epsilon && overlapY > Tolerance.Epsilon)
return true;
}
}
return false;
}
/// <summary>
/// Creates a seed pattern containing a single part positioned at the work area origin.
/// Returns an empty pattern if the part does not fit.
@@ -325,10 +384,25 @@ namespace OpenNest.Engine.Fill
var row = new List<Part>(pattern.Parts);
row.AddRange(TilePattern(pattern, direction, boundaries));
// Safety: if geometry-aware spacing produced overlapping parts,
// fall back to bbox-based spacing for this axis.
if (pattern.Parts.Count > 1 && HasOverlappingParts(row))
{
row = new List<Part>(pattern.Parts);
row.AddRange(TilePatternBbox(pattern, direction));
}
// If primary tiling didn't produce copies, just tile along perpendicular
if (row.Count <= pattern.Parts.Count)
{
row.AddRange(TilePattern(pattern, perpAxis, boundaries));
if (pattern.Parts.Count > 1 && HasOverlappingParts(row))
{
row = new List<Part>(pattern.Parts);
row.AddRange(TilePatternBbox(pattern, perpAxis));
}
return row;
}

16
OpenNest.Engine/Fill/PairFiller.cs
View File

@@ -321,9 +321,19 @@ namespace OpenNest.Engine.Fill
return cachedResult;
}
var remnantEngine = NestEngineRegistry.Create(plate);
var item = new NestItem { Drawing = drawing };
var parts = remnantEngine.Fill(item, remnantBox, null, token);
var filler = new FillLinear(remnantBox, partSpacing);
List<Part> parts = null;
foreach (var angle in new[] { 0.0, Angle.HalfPI })
{
token.ThrowIfCancellationRequested();
var result = FillHelpers.FillWithDirectionPreference(
dir => filler.Fill(drawing, angle, dir),
null, comparer, remnantBox);
if (result != null && result.Count > (parts?.Count ?? 0))
parts = result;
}
Debug.WriteLine($"[PairFiller] Remnant: {parts?.Count ?? 0} parts in " +
$"{remnantBox.Width:F2}x{remnantBox.Length:F2}");

35
OpenNest.Engine/Fill/StripeFiller.cs
View File

@@ -244,28 +244,29 @@ public class StripeFiller
return cachedResult;
}
FillStrategyRegistry.SetEnabled("Pairs", "RectBestFit", "Extents", "Linear");
try
var filler = new FillLinear(remnantBox, spacing);
List<Part> best = null;
foreach (var angle in new[] { 0.0, Angle.HalfPI })
{
var engine = CreateRemnantEngine(_context.Plate);
var item = new NestItem { Drawing = drawing };
var parts = engine.Fill(item, remnantBox, _context.Progress, _context.Token);
_context.Token.ThrowIfCancellationRequested();
var result = FillHelpers.FillWithDirectionPreference(
dir => filler.Fill(drawing, angle, dir),
null, _comparer, remnantBox);
Debug.WriteLine($"[StripeFiller] Remnant engine ({engine.Name}): {parts?.Count ?? 0} parts, " +
$"winner={engine.WinnerPhase}");
if (parts != null && parts.Count > 0)
{
FillResultCache.Store(drawing, remnantBox, spacing, parts);
return parts;
}
return null;
if (result != null && result.Count > (best?.Count ?? 0))
best = result;
}
finally
Debug.WriteLine($"[StripeFiller] Remnant linear: {best?.Count ?? 0} parts");
if (best != null && best.Count > 0)
{
FillStrategyRegistry.SetEnabled(null);
FillResultCache.Store(drawing, remnantBox, spacing, best);
return best;
}
return null;
}
public static double FindAngleForTargetSpan(