From d1109aaa43756235096466f9ac9fb23fa92a4f15 Mon Sep 17 00:00:00 2001
From: AJ Isaacs <ajisaacs27@gmail.com>
Date: Sun, 4 Oct 2026 21:22:29 -0400
Subject: [PATCH] fix(cutting): refuse uncertain native circular contacts

---
 .../Diagnostics/PostVerificationGeometry.cs   | 14 ++++
 .../NativeContactRegressionTests.cs           | 70 +++++++++++++++++++
 2 files changed, 84 insertions(+)
 create mode 100644 OpenNest.Tests/CuttingPlanning/NativeContactRegressionTests.cs

diff --git a/OpenNest.Core/Diagnostics/PostVerificationGeometry.cs b/OpenNest.Core/Diagnostics/PostVerificationGeometry.cs
index 4205a57..dc5798a 100644
--- a/OpenNest.Core/Diagnostics/PostVerificationGeometry.cs
+++ b/OpenNest.Core/Diagnostics/PostVerificationGeometry.cs
@@ -105,6 +105,20 @@ internal static class PostVerificationGeometry
         {
             var entity = ToEntity();
             var candidate = other.ToEntity();
+            // Native arc filters discard NaN supporting-circle intersections. Inspect
+            // both unfiltered queries first: roundoff can differ by operand direction.
+            // Coincident supports have separate overlap handling below.
+            if (Center is { } center && other.Center is { } otherCenter && !SameSupport(other))
+            {
+                var support = new Circle(center, Radius);
+                var otherSupport = new Circle(otherCenter, other.Radius);
+                support.Intersects(otherSupport, out var forward);
+                otherSupport.Intersects(support, out var reverse);
+                foreach (var point in forward)
+                    Validate(point);
+                foreach (var point in reverse)
+                    Validate(point);
+            }
             List<Vector> points;
             bool intersects;
             switch (candidate)
diff --git a/OpenNest.Tests/CuttingPlanning/NativeContactRegressionTests.cs b/OpenNest.Tests/CuttingPlanning/NativeContactRegressionTests.cs
new file mode 100644
index 0000000..6ed58ab
--- /dev/null
+++ b/OpenNest.Tests/CuttingPlanning/NativeContactRegressionTests.cs
@@ -0,0 +1,70 @@
+using OpenNest.CNC;
+using OpenNest.CNC.CuttingPlanning;
+using OpenNest.Diagnostics;
+using OpenNest.Geometry;
+
+namespace OpenNest.Tests.CuttingPlanning;
+
+public class NativeContactRegressionTests
+{
+    [Fact]
+    public void TangentArcLead_RefusesFilteredSupportingCircleNaNs()
+    {
+        var target = LeadMaterialSnapshot.Capture(LeadPathValidationTests.Rectangle(0, -1, 1, 1), Vector.Zero);
+        var obstacle = new Program();
+        obstacle.MoveTo(-0.22, 0.26);
+        obstacle.ArcTo(-0.22, 0.26, -0.22, 0.16, RotationType.CCW);
+        var material = LeadMaterialSnapshot.Capture(obstacle, Vector.Zero);
+        Assert.True(target.IsComplete, target.Reason);
+        Assert.True(material.IsComplete, material.Reason);
+        var lead = new Program();
+        lead.MoveTo(-0.2, 0);
+        lead.Codes.Add(new ArcMove(Vector.Zero, new Vector(-0.1, 0), RotationType.CW) { Layer = LayerType.Leadin });
+        lead.LineTo(0, 1);
+        var execution = ExecutionMotionReader.Read(lead, Vector.Zero, null, default);
+        var witness = new Vector(-0.16, 0.08);
+        Assert.True(execution.Motions[1].Curve.Contains(witness));
+        Assert.True(material.Rings[0][0].Contains(witness));
+        var result = LeadPathValidator.Check(execution, target, [material]);
+        Assert.False(result.IsComplete);
+        Assert.False(result.IsClear);
+    }
+
+    [Theory]
+    [InlineData(0.1, -0.22, 0.16)]
+    [InlineData(0.2, -0.28, 0.24)]
+    [InlineData(0.05, -0.19, 0.12)]
+    public void CircularNearTangency_BothDirectionsNeverCertifyNoContact(double radius, double x, double y)
+    {
+        var a = PostVerificationGeometry.Curve.Create(new Vector(-0.2, 0), Vector.Zero, new Vector(-0.1, 0), true);
+        var center = new Vector(x, y);
+        var b = PostVerificationGeometry.Curve.Create(center + new Vector(0, radius), center + new Vector(0, -radius), center, true);
+        foreach (var reverse in new[] { false, true })
+        {
+            try
+            {
+                var contacts = (reverse ? b : a).Contacts(reverse ? a : b, out var overlap);
+                Assert.True(overlap || contacts.Count > 0, "Near-tangent circular query silently certified no contact.");
+            }
+            catch (Exception ex) when (ex is ArgumentException or NotSupportedException)
+            {
+                // Numerical uncertainty is a refusal, never a disjoint certificate.
+            }
+        }
+    }
+
+    [Fact]
+    public void TouchingArcSplitHoles_RefuseMaterialCertificate()
+    {
+        var source = LeadPathValidationTests.Rectangle(-1, -1, 1, 1);
+        foreach (var center in new[] { new Vector(-0.1, 0), new Vector(-0.22, 0.16) })
+        {
+            source.MoveTo(center.X, center.Y + 0.1);
+            source.ArcTo(center.X, center.Y - 0.1, center.X, center.Y, RotationType.CCW);
+            source.ArcTo(center.X, center.Y + 0.1, center.X, center.Y, RotationType.CCW);
+        }
+        var snapshot = LeadMaterialSnapshot.Capture(source, Vector.Zero);
+        Assert.False(snapshot.IsComplete);
+        Assert.NotNull(snapshot.Reason);
+    }
+}