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fix(engine): use reverse-gap check in Compactor to handle irregular shapes

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The forward bounding-box gap check (gap < 0) incorrectly skipped obstacles
for irregular shapes like SULLYS-003 whose narrow handle extends past an
adjacent part's BB edge while the wide body still needs contact detection.
Replaced with a reverse-direction gap check that only skips obstacles the
moving part has entirely cleared. Also fixed edge distance check to prevent
overshooting the work area boundary when already at the limit.

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
This commit is contained in:
AJ Isaacs
2026-03-15 17:29:29 -04:00
parent 289a2044a6
commit 823320e982
1 changed files with 15 additions and 2 deletions
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17
OpenNest.Engine/Compactor.cs
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@@ -93,10 +93,15 @@ namespace OpenNest
var workArea = plate.WorkArea();
var distance = double.MaxValue;
// BB gap at which offset geometries are expected to be touching.
var contactGap = (halfSpacing + ChordTolerance) * 2;
foreach (var moving in movingParts)
{
var edgeDist = Helper.EdgeDistance(moving.BoundingBox, workArea, direction);
if (edgeDist > 0 && edgeDist < distance)
if (edgeDist <= 0)
distance = 0;
else if (edgeDist < distance)
distance = edgeDist;
var movingBox = moving.BoundingBox;
@@ -104,8 +109,16 @@ namespace OpenNest
for (var i = 0; i < obstacleBoxes.Length; i++)
{
// Use the reverse-direction gap to check if the obstacle is entirely
// behind the moving part. The forward gap (gap < 0) is unreliable for
// irregular shapes whose bounding boxes overlap even when the actual
// geometry still has a valid contact in the push direction.
var reverseGap = Helper.DirectionalGap(movingBox, obstacleBoxes[i], opposite);
if (reverseGap > 0)
continue;
var gap = Helper.DirectionalGap(movingBox, obstacleBoxes[i], direction);
if (gap < 0 || gap >= distance)
if (gap >= distance)
continue;
var perpOverlap = isHorizontal