Collision.HasOverlap re-triangulates both polygons on every call; Qwen
measured that as its dominant cost (over 400 s -> ~110 s on a 219-part
job once cached). TriangulatedRegion (from Qwen's TriSet) triangulates a
part once and takes translation as a parameter; it returns null when it
cannot decide so callers fall back to Collision, which stays the
reference. EdgeGridPolygon (from Qwen's FastPoly) certifies clearly
disjoint shells and never reports Clear for an overlap. A seeded harness
of 100,000 decisions (concave shapes, arcs, holes, touching contacts)
finds 0 mismatches against Collision.HasOverlap.
Co-Authored-By: Codex <noreply@openai.com>
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Core only had a convex NFP, so Opus55 and Gpt6Astra each built concave
NFPs from Clipper's Minkowski sum, and only Opus55 added the terms that
cover one part lying inside or swallowing the other - Gpt6Astra instead
filled every positive path and lost real interlocks. NoFitPolygon.Compute
ports Opus55's construction (boundary sweep united with A + p0 and
-B + a0; convex pairs use the linear edge merge). It works on filled
perimeters only; hole-aware clearance stays with collision testing.
Tests port Opus55's NFP tests and add a notch fit and a seeded property
check against Collision.HasOverlap.
Co-Authored-By: Codex <noreply@openai.com>
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Replace the Terra scaffold with an independent configuration-space contact placer and bounded stock-plan search. Include plugin tests, synthetic and DXF benchmark drivers, results, and deployment documentation.
Correct shared collision clipping and hole subtraction so curved-hole inserts validate consistently. Cover translated layouts, spacing violations, operand order, winding, and independent boolean-area comparisons.
Validation: 1,293 tests passed with 12 fixture skips; all 34 synthetic/generated and four DXF cases are valid and complete.
The Clipper validator flagged valid Opus55 and PEP layouts (P260805-03,
P260626-03). Two causes:
- Arc.ToPoints(circumscribe) scales every vertex out by 1/cos(step/2),
endpoints included, so a 0.03125 corner fillet flattened at 0.01 poked
0.013 past the straight edges it meets. ClipperBridge now flattens itself:
circumscribed arcs keep their endpoints on the arc and put interior
vertices on tangent intersections, with the segment count chosen so the
outward error stays within the tolerance. Arc.ToPoints is unchanged for
its other callers.
- The conservative padding made a layout exactly at the spacing fail.
NestValidator now uses OffsetForValidation: the same conservative
flattening, round joins at a tenth of the tolerance, no padding. Its only
leniency is that join chord error at convex corners.
With both, Opus55 is valid on all 26 benchmark jobs (25 before the
Clipper migration; the old failure was a spike artifact).
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
GetOffsetPerimeterEntities/GetOffsetPartEntities feed directional-distance
loops (FillLinear, Compactor, RotationSlideStrategy) that handle arcs
natively. Switching them to Clipper line output (plan option B) made
OpenNest.Tests run 48s -> 8m19s, Fill tests ~3x slower, and broke 20
exact-fit tests through tessellation and conservative padding, so they keep
the per-entity offset (option A), hardened:
- Arc, Circle and Line offsets are now side-symmetric. Right on a CCW arc
shrank instead of growing, Right on a CW circle grew, and Right on a line
offset to the left and reversed it. Only Left was used on hot paths, so
this was latent (SimplifierViewer drew both tolerance bands on one side).
- Shape.OffsetEntity closes every gap between consecutive offset pieces:
convex non-tangent line/arc corners get a round join about the original
corner, lines across a collapsed fillet are mitered, and any other gap
(concave arc corner, collapsed entity) is bridged with a line. Before,
only line-line corners were joined, so a vertex could slip through.
- Zero-area spikes are left in place and documented: they lie inside the
offset envelope, which is harmless for directional distance.
- OffsetOutward/OffsetInward become internal; PartGeometry is their only
caller.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Collision stays hand-rolled because it is the reference for a future GPU
kernel, but its inputs now come from Clipper region offsets. Pin down that
lines-only, round-join, 1e-4-precision polygons keep the contact and
part-in-part semantics: a neighbor inside a collapsed slot, a part inside
a hole that shrank by the spacing, and zero-spacing edge contact.
Document which steps are per-polygon preparation to cache and upload once,
and which are per-pair kernel-shaped work.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Its callers now take Clipper region offsets, which never produce the
self-intersections it patched over (and it only caught proper crossings,
so spikes survived it anyway). Polygon.OffsetEntity was its last caller;
the override is required by Entity but has no callers, so it becomes a
Clipper miter offset that keeps the Left/Right semantics and the input
winding. FindCrossing, SplitAtCrossing, SegmentsIntersect and the static
CalculateArea helper go with it.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Per-entity offsetting left spikes and inverted loops wherever a feature is
narrower than the spacing (1.nest), and RemoveSelfIntersections only
caught proper crossings. The callers that already flatten to polygons now
take a single Clipper region offset instead:
- PolygonHelper (BestFit) and PartBoundary use the conservative mode, which
keeps their never-under-estimate guarantee. PartBoundary also keeps holes
that appear when a perimeter curls back on itself.
- NestValidator offsets perimeter and cutouts in one region; Clipper drops
collapsed cutouts, so the collapsed-or-flipped heuristic goes away.
- CutOff.IntersectPerimeter offsets through the bridge. The old
OffsetEntity(Left) grew CW perimeters but shrank CCW ones, so with the
plate's perimeter cache a cut-off ran through the part; slots narrower
than twice the clearance now close up instead of leaving a gap.
- GetOffsetPartLines (3 overloads) and the AddOffset* helpers had no
callers and are removed, as is EntityView's never-defined DRAW_OFFSET
block.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
NoFitPolygon.Compute, its triangulate-and-union MinkowskiSum branch and
UnionPolygons had no callers; only ComputeConvex (NfpSlideStrategy) is used.
The Clipper path helpers they relied on now live in ClipperBridge.
ConvexDecomposition.Triangulate stays because Collision uses it.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
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>
Part.Intersects has been silently non-functional everywhere it's used.
Shape.ToPolygon()/ToPolygonWithTolerance() never called UpdateBounds(),
so every freshly-built polygon kept Entity's constructor-default
zero-size bounding box regardless of its actual vertices. Collision.Check's
first step is a bounding-box pre-filter, and a zero-size box can never
overlap anything, so it always short-circuited to "no overlap" no matter
what the real geometry looked like.
That masked a second bug: Part.Intersects built its polygons via the
unconditional 1000-segments-per-arc ToPolygon() default instead of an
adaptive tolerance. For parts with several small fillets/holes this
produced tens of thousands of vertices, making the now-correct bbox
check fall through into a triangulation/clip step too slow to return
in practice. Switched to ToPolygonWithTolerance at a named tolerance
matching PartGeometry's existing convention.
PairEvaluator's own Keep/overlap check had a third, independent bug:
it used Shape.Intersects (edge-crossing detection only) at a coarse
0.01 chord tolerance, which misses containment-style overlaps and can
polygonize rounded corners coarsely enough to hide a genuine sliver
overlap. Switched to Collision.HasOverlap (full polygon clip, handles
containment) at a tighter dedicated tolerance.
Verified against a real nest file: PairFiller was tiling a BestFit
pair that PairEvaluator had incorrectly marked Keep=true, producing
visibly overlapping parts on the plate that no downstream overlap
check ever caught.
Known follow-up: OpenNest.Tests.BestFit.BestFitOverlapTests.KeptPairs_NoOverlap
still fails on 3/1082 synthetic candidates that overlap by a sub-0.001
sliver right at a rounded-corner tangent point — a separate, much
smaller precision edge case in PairEvaluator's raw (pre-transform)
coordinate frame, not a regression from this change.
Delete OpenNest.Engine/Nfp (AutoNester, BottomLeftFill, NfpCache,
SimulatedAnnealing, INestOptimizer, PlacedPart, SequenceEntry), the Core
InnerFitPolygon, and the NestPhase.Nfp member. None had callers outside the
folder: console --autonest and MCP autonest_plate call engine.Nest(), not
AutoNester.
Drop the Nfp cases from NestPhaseExtensionsTests, fix the --autonest help
text, and update CLAUDE.md. NoFitPolygon stays; BestFit pair evaluation
still uses it.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Repo-wide sweep with the pinned CSharpier 1.3.0 tool. Whitespace and
line-wrapping only; OpenNest.Engine.Tests (109) and OpenNest.IO.Tests
pass after reformat, full solution builds 0 errors.
Added .csharpierignore so csproj/config XML keeps its existing layout
(CSharpier's XML wrapping churns attributes with zero benefit).
Formatting is now enforceable: dotnet csharpier check . passes.
The witness-probe overlap test missed small corner intersections: its
candidate points (crossing-edge midpoints and vertex-centroid midpoints)
can all land on a part boundary or outside the intersection, so two 10x10
parts at (0,0) and (9,9) with zero spacing were accepted despite sharing
a 1x1 unit of material.
Route the overlap decision through Collision, which clips triangulated
polygons and keeps only positive-area regions, catching corner overlaps,
containment, and coincident poses while legal edge/corner contact stays
legal. Collision's hole subtraction was conservative (partially-clipped
triangles were kept whole), so a part inside another part's cutout could
false-positive depending on triangulation alignment; subtract holes
exactly instead: a piece outside a convex hole triangle is the union of
its clips against each edge's outside half-space.
GeometrySimplifier/ArcFit now fit arcs that pass exactly through run
endpoints while balancing tangency error between trusted and estimated
directions, fixing arcs that previously bulged or broke tangent
continuity at fillet/compound-curve junctions.
GravographIS post processor gains per-layer (engrave/cut) tool passes
via a new GravographISPostConfig, so ENGRAVE/ETCH-tagged geometry runs
as a separate scribe pass with its own feed/depth and an operator
pause before the cut pass (spring-floated spindle needs a tool swap).
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
Duplicate circle entities at the same location inflated pierce counts
and cut pricing (e.g. SULLYS-035 showed 9 pierces instead of 8).
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
Near-zero-sweep arcs with large radius (e.g. from ellipse converter) have
nearly-coincident start/end points. Downstream code (ConvertProgram, Program
BoundingBox) treats coincident start/end as a full 360° circle, inflating the
bounding box and rendering wrong geometry. Emit a LinearMove when sweep is
negligible — geometrically equivalent and avoids the ambiguity. Also fix the
ellipse converter to produce lines instead of degenerate arcs at the source.
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
Arcs with sweep angles smaller than Tolerance.Epsilon were treated as
full circles by IsBetweenRad's shortcut check, causing UpdateBounds to
expand the bounding box to Center ± Radius. This made zoom-to-fit zoom
out far beyond the actual part extents.
Skip cardinal angle expansion when sweep is near-zero so the bounding
box uses only the arc's start/end points.
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
ArcToLineClosestDistance used geometric closest-point as a proxy for
directional push distance, which are fundamentally different queries.
The heuristic could overestimate the safe push distance when an arc
faces an inclined line, causing the Compactor to over-push parts into
overlapping positions.
Replace with analytical computation: for each arc/line pair, solve
dt/dθ = 0 to find the two critical angles where the directional
distance is stationary, evaluate both (if within the arc's angular
span), and fire a ray to verify the hit is within the line segment.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Merge the near-identical Left/Right and Up/Down pruning loops into a
single loop that selects the perpendicular axis via IsHorizontalDirection().
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
ShapeProfile.NormalizeEntities called Shape.Reverse() which flipped arc
directions on the original entity objects shared with the CAD view. Switching
to the Program tab and back would leave arcs reversed. Clone entities before
normalizing so the originals stay untouched.
Adds abstract Entity.Clone() with implementations on Line, Arc, Circle,
Polygon, and Shape (deep-clones children). Also adds CloneAll() extension
and replaces manual duplication in PartGeometry.CopyEntitiesAtLocation and
ProgramEditorControl.CloneEntity.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Entities now have a Guid Id for stable identity across edit sessions.
Drawing stores the full source entity set (SourceEntities) and a set of
suppressed entity IDs (SuppressedEntityIds), replacing the previous
SuppressedProgram approach. Unchecked entities in the converter are
suppressed rather than permanently removed, so they can be re-enabled
when editing drawings again.
Entities are serialized as JSON in the nest file (entities/entities-N)
alongside the existing G-code programs. Backward compatible with older
nest files that lack entity data.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Extract ArcToLineClosestDistance helper to eliminate duplicate Phase 3
arc-to-line loops, remove redundant MaxValue guard in curve-to-curve
check, consolidate CollectVertices overloads, and add entity-based
PushDirection overload for API consistency.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Corner arcs from offset perimeters could slip past vertex sampling,
causing compactor push to undershoot by ~halfSpacing. Use ClosestPointTo
to find the actual nearest point on each arc to each line before firing
the directional ray.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Pull duplicated vertex collection, edge conversion, sorting, and
ray-circle solving into reusable private methods. Delegate the
no-offset DirectionalDistance overload to the offset version.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
The vertex-to-entity approach in DirectionalDistance only sampled 4
cardinal points per circle, missing the true closest contact when
circles are offset diagonally from the push direction. This caused
the distance to be overestimated, pushing circles too far and
creating overlap that worsened with distance from center.
Add a curve-to-curve pass that computes exact contact distance by
treating the problem as a ray from one center to an expanded circle
(radius = r1 + r2) at the other center. Includes arc angular range
validation for arc-to-arc and arc-to-circle cases.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Circle.Rotation was lost in three places, causing reversed circles to
still offset inward instead of outward:
- ConvertGeometry.AddCircle hardcoded CCW instead of using circle.Rotation
- ConvertProgram.AddArcMove created Circle without setting Rotation from arc
- Shape.OffsetOutward/OffsetInward copied Circle without setting Rotation
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
- Add entity-based DirectionalDistance overload to SpatialQuery that
uses RayArcDistance/RayCircleDistance instead of tessellating arcs
and circles into line segments
- Add GetOffsetPartEntities, GetPerimeterEntities, GetPartEntities to
PartGeometry for non-tessellated entity extraction
- Update Compactor.Push to use native entities instead of tessellated
lines — 952 circles = 952 entities vs ~47,600 line segments
- Use bounding box containment check to skip cutout entities when no
obstacle is inside the moving part (perimeter-only for common case)
- Obstacles always use perimeter-only entities since cutout edges are
inside the solid and cannot block external parts
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
- Try all valid best fit pairs instead of only the first when qty=2,
picking the best via IsBetterFill comparer (fixes suboptimal plate
selection during auto-nesting)
- Pre-compute best fits across all plate sizes once via
BestFitCache.ComputeForSizes instead of per-size GPU evaluation
- Early exit plate optimizer when all items fit (salvage < 100%)
- Trim slide offset sweep range to 50% overlap to reduce candidates
- Use actual geometry (ray-arc/ray-circle intersection) instead of
tessellated polygons for slide distance computation — eliminates
the massive line count from circle/arc tessellation
- Add RayArcDistance and RayCircleDistance to SpatialQuery
- Add PartGeometry.GetOffsetPerimeterEntities for non-tessellated
perimeter extraction
- Disable GPU slide computer (slower than CPU currently)
- Remove dead SelectBestFitPair virtual method and overrides
Reduces best fit computation from 7+ minutes to ~4 seconds for a
73x25" part with 30+ holes on a 48x96 plate.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Circle.ToPoints() always generated CCW points regardless of the Rotation
property, so reversing a circle contour in the CAD converter had no effect.
Now negates the step angle when Rotation is CW, matching Arc.ToPoints behavior.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Box constructor and derived properties (Right, Top, Center, Translate, Offset)
had Width and Length swapped — Length is X axis, Width is Y axis. Corrected
across Core geometry, plate bounding box, rectangle packing, fill algorithms,
tests, and UI renderers.
Added FillSpiral with center remnant detection and recursive FillBest on
the gap between the 4 spiral quadrants. RectFill.FillBest now compares
spiral+center vs full best-fit fairly. BestCombination returns a
CombinationResult record instead of out params.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Priority-based snapping: when the cursor is within 10px of an entity
endpoint or midpoint, snaps to it instead of the nearest contour point.
Diamond marker (endpoint) or triangle marker (midpoint) replaces the
lime dot to indicate active snap. Also refactors OnPaint into focused
helper methods and adds Arc.MidPoint().
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Add ArcFit.FitWithDualTangent to constrain replacement arcs to match
tangent directions at both endpoints, preventing kinks without
introducing gaps. Add DXF year selection to CAD converter export.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Remove pass-through wrappers (FitWithStartTangent, MaxRadialDeviation), extract
PerpendicularDistance and NormalizeAngle helpers to deduplicate mirror axis math,
convert GetExitDirection to switch expression, and simplify ComputeEndTangent.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
OffsetOutward now normalizes to CW winding before offsetting instead of
trial-and-error with bounding box comparison. CadConverterForm designer
regenerated with new entityView1 properties.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Polygon-polygon collision detection using convex decomposition (ear-clipping
triangulation) followed by Sutherland-Hodgman clipping on each triangle pair.
Handles overlapping, non-overlapping, edge-touching, containment, and concave
polygons. Includes hole subtraction support for future use.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Immutable result type that holds overlap flag, overlap regions (as polygons),
intersection points, and computed overlap area.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
EllipseConverter computed arc radius from start point only, causing
~0.0009 unit gaps between consecutive arcs. Use circumcircle of
(start, mid, end) points so both endpoints lie exactly on the arc.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
The arc and line Optimize methods had identical merge-loop structure;
extract a generic MergePass helper with type-specific delegates.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Move identical FitWithStartTangent and MaxRadialDeviation methods
to a shared ArcFit class, eliminating 40-line duplicate.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Convex corners were being miter-joined (lines extended to a point)
because IntersectsUnbounded always finds an intersection for non-parallel
lines. Now checks the cross product of original line directions to detect
convex corners and inserts an arc instead.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
UpdateEtchEntities was removing all entities on the ETCH layer, which
also deleted user-added etch marks like part numbers. Now tags generated
bend etch lines with a BendEtch tag and filters on that instead.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Etch marks for up bends are now real geometry entities on an ETCH layer
instead of being drawn dynamically. They flow through the full pipeline:
entities → FilterPanel layers → ConvertGeometry (tagged as Scribe) →
post-processor sequencing before cut geometry.
Also includes ShapeProfile normalization (CW perimeter, CCW cutouts)
applied consistently across all import paths, and inward offset support
for cutout shapes in overlap/offset polygon calculations.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Add argument validation to EllipseConverter.Convert for tolerance and
semi-axis parameters. Narrow bare catch in Extensions.cs spline method
to log via Debug.WriteLine. Remove unused lineCount variable from
SolidWorksBendDetectorTests.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
