feat(geometry): add ClipperBridge for region offsetting
Offsetting entity by entity leaves spikes and inverted loops wherever a feature is narrower than the spacing, and RemoveSelfIntersections only catches proper crossings. ClipperBridge flattens a ShapeProfile into one region (perimeter positive, cutouts negative) and inflates it in a single Clipper pass with round joins, so narrow features collapse and holes that close up disappear. Conservative mode circumscribes perimeter arcs, inscribes cutout arcs and pads the inflation by the chord tolerance, so the result never under-estimates the spacing. It replaces the circumscribed-polygon guarantee the BestFit/PartBoundary callers rely on. Clipper stays confined to CPU preparation whose output is cached; the per-pair Collision path remains hand-rolled for GPU portability. LayoutPart's display offset now goes through the bridge. Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
This commit is contained in:
Claude Opus 5.5
@@ -0,0 +1,281 @@
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using System.IO;
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using System.Linq;
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using System.Text;
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using OpenNest.CNC;
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using OpenNest.Converters;
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using OpenNest.Geometry;
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using OpenNest.IO;
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namespace OpenNest.Tests.Geometry;
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public class ClipperBridgeTests
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{
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[Fact]
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public void Offset_NotchNarrowerThanTwiceSpacing_ClosesNotch()
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{
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// 10x10 square with a 0.3-wide, 3-deep slot down from the top edge.
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var profile = Profile(
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Poly(
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(0, 0),
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(10, 0),
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(10, 10),
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(5.15, 10),
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(5.15, 7),
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(4.85, 7),
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(4.85, 10),
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(0, 10)
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)
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);
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var result = ClipperBridge.Offset(profile, 0.25, 0.001);
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var outer = Assert.Single(result.Outers);
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Assert.Empty(result.Holes);
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// The slot fills in. Only a shallow dent is left where the round joins of the
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// two mouth corners meet: 10 + sqrt(0.25^2 - 0.15^2) = 10.2.
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Assert.DoesNotContain(outer.Vertices, v => v.X > 4.85 && v.X < 5.15 && v.Y < 10.199);
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var fullSquare = 10 * 10 + 4 * 10 * 0.25 + System.Math.PI * 0.25 * 0.25;
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Assert.InRange(outer.Area(), fullSquare - 0.01, fullSquare);
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}
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[Fact]
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public void Offset_HoleSmallerThanTwiceSpacing_DropsHole()
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{
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var profile = Profile(Poly((0, 0), (10, 0), (10, 10), (0, 10)), Circle(5, 5, 0.2));
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var result = ClipperBridge.Offset(profile, 0.25, 0.001);
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Assert.Single(result.Outers);
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Assert.Empty(result.Holes);
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}
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[Fact]
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public void Offset_HoleWithThinNeck_SplitsIntoTwoHoles()
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{
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// Two 2x2 pockets joined by a 2-long, 0.3-wide channel.
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var hole = Poly(
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(2, 4),
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(4, 4),
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(4, 4.85),
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(6, 4.85),
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(6, 4),
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(8, 4),
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(8, 6),
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(6, 6),
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(6, 5.15),
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(4, 5.15),
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(4, 6),
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(2, 6)
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);
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var profile = Profile(Poly((0, 0), (10, 0), (10, 10), (0, 10)), hole);
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var result = ClipperBridge.Offset(profile, 0.25, 0.001);
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Assert.Single(result.Outers);
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Assert.Equal(2, result.Holes.Count);
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// Each pocket shrinks to 1.5x1.5, plus a small lobe toward the channel mouth
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// where the round joins of the channel corners meet.
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Assert.All(result.Holes, h => Assert.InRange(h.Area(), 2.25, 2.26));
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}
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[Fact]
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public void Offset_WindingOfInputDoesNotMatter()
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{
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var ccw = Poly((0, 0), (10, 0), (10, 10), (0, 10));
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var cw = Poly((0, 0), (0, 10), (10, 10), (10, 0));
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var hole = Circle(5, 5, 2);
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var a = ClipperBridge.Offset(Profile(ccw, hole), 0.25, 0.001);
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var b = ClipperBridge.Offset(Profile(cw, hole), 0.25, 0.001);
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Assert.Equal(a.Outers.Count, b.Outers.Count);
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Assert.Equal(a.Holes.Count, b.Holes.Count);
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Assert.Equal(a.Outers[0].Area(), b.Outers[0].Area(), 6);
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Assert.Equal(a.Holes[0].Area(), b.Holes[0].Area(), 6);
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}
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[Fact]
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public void Offset_Circumscribe_NeverUnderestimatesDistance()
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{
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const double spacing = 0.25;
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var profile = Profile(Circle(0, 0, 5), Circle(0, 0, 3));
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var result = ClipperBridge.Offset(profile, spacing, 0.05, circumscribe: true);
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var outer = Assert.Single(result.Outers);
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var hole = Assert.Single(result.Holes);
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for (var i = 0; i < 360; i++)
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{
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var a = i * System.Math.PI / 180;
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var onPerimeter = new Vector(5 * System.Math.Cos(a), 5 * System.Math.Sin(a));
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var onCutout = new Vector(3 * System.Math.Cos(a), 3 * System.Math.Sin(a));
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Assert.True(outer.ContainsPoint(onPerimeter));
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Assert.True(
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outer.ClosestPointTo(onPerimeter).DistanceTo(onPerimeter) >= spacing,
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$"Perimeter sample at {i} deg is closer than the spacing."
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);
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Assert.False(hole.ContainsPoint(onCutout));
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Assert.True(
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hole.ClosestPointTo(onCutout).DistanceTo(onCutout) >= spacing,
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$"Cutout sample at {i} deg is closer than the spacing."
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);
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}
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}
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[Fact]
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public void Offset_PepNotchedPart_HasNoSpikes()
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{
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// 1.nest (PEP P260417-06): rounded-square hole, perimeter with 0.0598-wide
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// notches and 0.015 fillets, all narrower than twice the 0.25 spacing.
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var program = ReadProgram(PepNotchedPart);
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var entities = ConvertProgram.ToGeometry(program)
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.Where(e => e.Layer != SpecialLayers.Rapid)
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.ToList();
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var result = ClipperBridge.Offset(new ShapeProfile(entities), 0.25, 0.001);
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var outer = Assert.Single(result.Outers);
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Assert.Single(result.Holes);
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var verts = outer.Vertices;
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var n = verts.Count - 1;
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for (var i = 0; i < n; i++)
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{
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for (var j = i + 2; j < n; j++)
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{
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if (i == 0 && j == n - 1)
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continue;
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Assert.False(
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SegmentsCross(verts[i], verts[i + 1], verts[j], verts[j + 1]),
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$"Edges {i} and {j} cross."
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);
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}
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}
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for (var i = 0; i < n; i++)
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{
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var prev = verts[(i + n - 1) % n];
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var cur = verts[i];
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var next = verts[(i + 1) % n];
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var inDir = Unit(cur - prev);
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var outDir = Unit(next - cur);
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var dot = inDir.X * outDir.X + inDir.Y * outDir.Y;
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Assert.True(dot > -0.99, $"Spike at vertex {i} ({cur.X:F4}, {cur.Y:F4}).");
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}
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}
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private static bool SegmentsCross(Vector a, Vector b, Vector c, Vector d)
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{
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static double Cross(Vector o, Vector p, Vector q) =>
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(p.X - o.X) * (q.Y - o.Y) - (p.Y - o.Y) * (q.X - o.X);
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return Cross(c, d, a) * Cross(c, d, b) < 0 && Cross(a, b, c) * Cross(a, b, d) < 0;
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}
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private static Vector Unit(Vector v)
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{
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var len = System.Math.Sqrt(v.X * v.X + v.Y * v.Y);
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return new Vector(v.X / len, v.Y / len);
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}
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private static Shape Poly(params (double X, double Y)[] pts)
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{
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var shape = new Shape();
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for (var i = 0; i < pts.Length; i++)
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{
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var a = pts[i];
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var b = pts[(i + 1) % pts.Length];
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shape.Entities.Add(new Line(a.X, a.Y, b.X, b.Y));
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}
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return shape;
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}
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private static Shape Circle(double x, double y, double r)
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{
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var shape = new Shape();
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shape.Entities.Add(new Circle(x, y, r));
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return shape;
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}
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private static ShapeProfile Profile(params Shape[] shapes) =>
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new(shapes.SelectMany(s => s.Entities).ToList());
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private static Program ReadProgram(string gcode)
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{
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using var stream = new MemoryStream(Encoding.UTF8.GetBytes(gcode));
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return new ProgramReader(stream).Read();
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}
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private const string PepNotchedPart = """
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G91
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G00X-8.003411Y12.354904
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G01X0Y5.03125
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G03X-2.3125Y2.3125I-2.3125J0
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G01X-10.0625Y0
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G03X-2.3125Y-2.3125I0J-2.3125
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G01X0Y-10.0625
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G03X2.3125Y-2.3125I2.3125J0
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G01X10.0625Y0
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G03X2.3125Y2.3125I0J2.3125
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G01X0Y5.03125
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G00X10.200865Y-12.347161
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G01X-2.182454Y0
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G03X-0.015Y-0.015I0J-0.015
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G01X0Y-1.457646
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G02X-0.015Y-0.015I-0.015J0
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G01X-30.664322Y0
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G02X-0.015Y0.015I0J0.015
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G01X0Y1.1725
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G01X0.072967Y0.149903
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G02X0.013487Y0.008435I0.013487J-0.006565
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G01X0.620707Y0
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G03X0.015Y0.015I0J0.015
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G01X0Y0.396469
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G03X-0.015Y0.015I-0.015J0
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G01X-0.4225Y0
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G01X0Y0.095339
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G01X-2.419615Y0
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G02X-0.0625Y0.0625I0J0.0625
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G01X0Y23.809322
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G02X0.0625Y0.0625I0.0625J0
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G01X2.405015Y0
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G03X0.015Y0.015I0J0.015
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G01X0Y1.837647
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G02X0.015Y0.015I0.015J0
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G01X4.005139Y0
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G02X0.015Y-0.015I0J-0.015
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G01X0Y-0.3573
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G03X0.0598Y0I0.03J0
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G01X0Y0.974934
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G02X0.0625Y0.0625I0.0625J0
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G01X25.420246Y0
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G02X0.0625Y-0.0625I0J-0.0625
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G01X0Y-0.974934
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G03X0.0598Y0I0.03J0
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G01X0Y0.3573
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G02X0.015Y0.015I0.015J0
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G01X0.679276Y0
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G02X0.015Y-0.015I0J-0.015
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G01X0Y-1.457647
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G03X0.015Y-0.015I0.015J0
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G01X1.145147Y0
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G02X0.015Y-0.015I0J-0.015
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G01X0Y-0.709988
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G03X0.015Y-0.015I0.015J0
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G01X0.944807Y0
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G02X0.0625Y-0.0625I0J-0.0625
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G01X0Y-23.891834
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""";
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}
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