diff --git a/OpenNest.Core/Part.cs b/OpenNest.Core/Part.cs
index 1bfdd7f..edf64da 100644
--- a/OpenNest.Core/Part.cs
+++ b/OpenNest.Core/Part.cs
@@ -177,15 +177,16 @@ namespace OpenNest
             if (!perimeter1.Intersects(perimeter2, out var rawPts))
                 return false;
 
-            // Exclude intersection points that coincide with vertices of BOTH
-            // perimeters — these are touch points (shared corners/endpoints),
+            // Exclude intersection points that coincide with a vertex of either
+            // perimeter — these are boundary contact points (shared corners,
+            // endpoints, or a corner touching an edge) with zero area overlap,
             // not actual crossings where one shape enters the other's interior.
             var verts1 = CollectVertices(perimeter1);
             var verts2 = CollectVertices(perimeter2);
 
             foreach (var pt in rawPts)
             {
-                if (IsNearAnyVertex(pt, verts1) && IsNearAnyVertex(pt, verts2))
+                if (IsNearAnyVertex(pt, verts1) || IsNearAnyVertex(pt, verts2))
                     continue;
                 pts.Add(pt);
             }
diff --git a/OpenNest.Core/PartGeometry.cs b/OpenNest.Core/PartGeometry.cs
index 43bdfb4..ce68f53 100644
--- a/OpenNest.Core/PartGeometry.cs
+++ b/OpenNest.Core/PartGeometry.cs
@@ -45,7 +45,7 @@ namespace OpenNest
             var profile = new ShapeProfile(
                 entities.Where(e => e.Layer != SpecialLayers.Rapid).ToList());
             var lines = new List<Line>();
-            var totalSpacing = spacing + chordTolerance;
+            var totalSpacing = spacing;
 
             AddOffsetLines(lines, profile.Perimeter.OffsetOutward(totalSpacing),
                 chordTolerance, part.Location);
@@ -63,7 +63,7 @@ namespace OpenNest
             var profile = new ShapeProfile(
                 entities.Where(e => e.Layer != SpecialLayers.Rapid).ToList());
             var lines = new List<Line>();
-            var totalSpacing = spacing + chordTolerance;
+            var totalSpacing = spacing;
 
             AddOffsetDirectionalLines(lines, profile.Perimeter.OffsetOutward(totalSpacing),
                 chordTolerance, part.Location, facingDirection);
@@ -97,7 +97,7 @@ namespace OpenNest
             var profile = new ShapeProfile(
                 entities.Where(e => e.Layer != SpecialLayers.Rapid).ToList());
             var lines = new List<Line>();
-            var totalSpacing = spacing + chordTolerance;
+            var totalSpacing = spacing;
 
             AddOffsetDirectionalLines(lines, profile.Perimeter.OffsetOutward(totalSpacing),
                 chordTolerance, part.Location, facingDirection);
diff --git a/OpenNest.Engine/NestEngineBase.cs b/OpenNest.Engine/NestEngineBase.cs
index b60fd0d..f9a5f9e 100644
--- a/OpenNest.Engine/NestEngineBase.cs
+++ b/OpenNest.Engine/NestEngineBase.cs
@@ -2,6 +2,7 @@ using OpenNest.Engine;
 using OpenNest.Engine.Fill;
 using OpenNest.Engine.Strategies;
 using OpenNest.Geometry;
+using OpenNest.Math;
 using System;
 using System.Collections.Generic;
 using System.Diagnostics;
@@ -275,8 +276,12 @@ namespace OpenNest
                 {
                     var box2 = parts[j].BoundingBox;
 
-                    if (box1.Right < box2.Left || box2.Right < box1.Left ||
-                        box1.Top < box2.Bottom || box2.Top < box1.Bottom)
+                    var overlapX = System.Math.Min(box1.Right, box2.Right)
+                                 - System.Math.Max(box1.Left, box2.Left);
+                    var overlapY = System.Math.Min(box1.Top, box2.Top)
+                                 - System.Math.Max(box1.Bottom, box2.Bottom);
+
+                    if (overlapX <= Tolerance.Epsilon || overlapY <= Tolerance.Epsilon)
                         continue;
 
                     List<Vector> pts;