FillGrid had no overlap check after perpendicular tiling of the row
pattern (Step 2), unlike Step 1 which had one. When geometry-aware
FindPatternCopyDistance underestimated row spacing, overlapping parts
were returned unchecked.
Changes:
- Make FillLinear.HasOverlappingParts shape-aware (bbox pre-filter +
Part.Intersects) instead of bbox-only, preventing false positives on
interlocking pairs while catching real overlaps
- Add missing overlap safety check after Step 2 perpendicular tiling
with bbox fallback
- Add diagnostic Debug.WriteLine logging when overlap fallback triggers,
including engine label, step, direction, work area, spacing, pattern
details, and overlapping part locations/rotations for reproduction
- Add FillLinear.Label property set at all callsites for log traceability
- Refactor LinearFillStrategy and ExtentsFillStrategy to use shared
FillHelpers.BestOverAngles helper for angle-sweep logic
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>
Extract shared BestFitAxis helper parameterized by orientation,
eliminating 23-line duplicate in rectangle packing.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
StripeFiller and FillExtents had identical 24-line overlap detection
methods; move to FillHelpers and delegate from both callers.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Extract shared EvenlyDistribute helper parameterized by axis,
eliminating 27-line duplicate between the two methods.
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>
Both ActionSelect and ActionZoomWindow had identical 29-line
GetRectangle methods; consolidate into the common base class.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
The parameterless rotation is equivalent to rotating around (0,0),
so delegate to the origin overload to eliminate 30-line duplicate.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Extract shared FillAxis helper parameterized by orientation,
eliminating 34-line duplicate between horizontal and vertical fills.
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>
Extract shared SortStrips helper parameterized by axis selectors,
eliminating 61-line near-duplicate between column and row sorting.
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>
- Part.Intersects: filter intersection points at a vertex of either
shape (was both), so edge-touching parts are not flagged as overlapping
- NestEngineBase.HasOverlaps: use epsilon-based bounding box pre-filter
consistent with FillExtents and Plate.HasOverlappingParts
- PartGeometry.GetOffsetPartLines: remove extra chordTolerance added to
spacing offset — was causing 0.002" gap beyond the intended part spacing
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>
Place circle labels on the circumference using golden angle distribution
so concentric circles don't overlap. Hide labels when the entity is too
small on screen to fit the badge.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Labels are drawn at each entity's midpoint with a filled background
circle for readability. Toggle via "Labels" checkbox in the detail bar.
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>
Shape.OffsetOutward produces inward offsets for certain rotated polygons,
causing geometry-aware copy distances to be too small and placing
overlapping parts. Root cause is in the offset winding direction
detection — this commit adds safety nets while that is investigated.
- FillLinear.FillGrid: detect bbox overlaps after geometry-aware tiling,
fall back to bbox-based spacing when overlaps found
- FillExtents.RepeatColumns: detect overlaps after Compactor computes
copy distance, fall back to columnWidth + spacing
- PairFiller/StripeFiller remnant fills: use FillLinear directly instead
of spawning full engine pipeline (avoids strategies with the bug)
- Add PairOverlapDiagnosticTests reproducing the issue
- MCP config: use shadow-copy wrapper for dev hot-reload
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
High-utilization pairs (>=75%) are no longer discarded for exceeding
the aspect ratio limit, since the material isn't being wasted.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Wires the OpenNest.Data layer into the UI: adds project reference, creates MachineConfigForm (tree-based editor for machines/materials/thicknesses with import/export), and adds Tools > Machine Configuration... menu item.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Embeds CL-980.json as a resource in OpenNest.Data and adds EnsureDefaults()
to LocalJsonProvider, which seeds the machines directory on first run when empty.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
One JSON file per machine named by GUID, stored in a configurable directory.
Supports save, load, list (as summaries), and delete with IO-error retry.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
- Parts tab: shows all BOM items, editable Material/Thickness for
matched rows, grayed-out rows for items without DXF files
- Groups tab: auto-computed from parts with editable Plate Width/Length
per material+thickness group
- Editing Material/Thickness on Parts tab immediately re-groups
- Per-group plate sizes preserved across re-groups
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Fill must be at index 0 (front) so it's processed last by the
docking layout engine. Edge docks at higher indices process first.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
AutoSize with Dock.Fill child causes circular sizing and collapses
the GroupBox. Use fixed Height=200 instead.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Replaced absolute-positioned controls with TableLayoutPanel in the input
section and Dock-based layout for bottom buttons. Fixes controls being
hidden at non-100% DPI scaling.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
- Add Fill control last so edge-docked controls get space first
- Remove stale hardcoded Location on bottom panel
- Switch to Sizable border with MinimumSize so user can resize
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
- Fix critical: use MdiParentForm (custom property) instead of MdiParent
(WinForms property) in ImportBom_Click to avoid InvalidOperationException
- Add null guard in CreateNests_Click
- Set Drawing.Material from BOM group
- Move DxfImporter creation outside loop
- Improve summary label text with reason descriptions
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Task 9: CreateNests_Click validates plate dimensions, then for each
MaterialGroup creates a Nest with name '{job} - {thickness} {material}',
sets PlateDefaults (size, thickness, material, quadrant=1, spacing),
imports each matched DXF via DxfImporter, converts entities to Program
with leading RapidMove offset handling (same pattern as CadConverterForm),
sets Quantity.Required from BOM qty, then opens an EditNestForm for each
nest that has drawings. Summary MessageBox reports count and import errors.
Co-Authored-By: Claude Sonnet 4.6 <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>
Add EllipseConverter static class with foundational methods for converting
ellipse parameters to circular arcs: EvaluatePoint, EvaluateTangent,
EvaluateNormal, and IntersectNormals. All 8 unit tests pass.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
When a file is loaded, a background task analyzes the entities for
simplification candidates and highlights the Simplify button with a
count when candidates are found. Button resets after simplification
is applied.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
OptionsForm now shows checkboxes for each fill strategy, persisted via
the new DisabledStrategies user setting. FillStrategyRegistry exposes
AllStrategies and DisabledNames for the UI. MainForm applies disabled
strategies on startup via OptionsForm.ApplyDisabledStrategies().
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
New EngineOverlapTests verifies all engine types produce overlap-free
results. New StrategyOverlapTests checks each fill strategy individually.
StripeFillerTests updated to verify returned parts are overlap-free
rather than just asserting non-empty results. Remove obsolete FitCircle
tests from GeometrySimplifierTests (method was removed).
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
FillExtents falls back to the unadjusted column when iterative pair
adjustment shifts parts enough to cause genuine overlap. StripeFiller
rejects grid results where bounding boxes overlap, which can occur when
angle convergence produces slightly off-axis rotations.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Part.Intersects now filters out intersection points that coincide with
vertices of both perimeters (shared corners/endpoints), which are touch
points rather than actual crossings. Plate.HasOverlappingParts adds a
bounding box pre-filter requiring overlap region to exceed Epsilon in
both dimensions before performing expensive shape intersection checks.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Convert SimplifierViewerForm to partial class with standard WinForms
designer pattern. UI controls are now defined in the .Designer.cs file
with InitializeComponent(), enabling visual designer support.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Three bugs prevented the simplifier from working on ellipse geometry:
1. Sweep angle check blocked initial fit — the 5-degree minimum sweep
was inside TryFit(), killing candidates before the extension loop
could accumulate enough segments. Moved to TryFitArcAt() after
extension.
2. Layer reference equality split runs — entities from separate DXF
ellipses had different Layer object instances for the same layer "0",
splitting them into independent runs. Changed to compare Layer.Name.
3. Symmetrize replaced arcs with mirrored copies whose endpoints didn't
match the target's original geometry, creating ~0.014 gaps. Now only
applies mirrored arcs when endpoints are within tolerance of the
target's boundary points.
Also: default tolerance 0.02 -> 0.004, Export DXF button in
CadConverterForm for debugging simplified geometry.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Geometry Simplifier:
- Replace least-squares circle fitting with mirror axis algorithm
that constrains center to perpendicular bisector of chord, guaranteeing
zero-gap endpoint connectivity by construction
- Golden section search optimizes center position along the axis
- Increase default tolerance from 0.005 to 0.5 for practical CNC use
- Support existing arcs in simplification runs (sample arc points to
find larger replacement arcs spanning lines + arcs together)
- Add tolerance zone visualization (offset original geometry ±tolerance)
- Show original geometry overlay with orange dashed lines in preview
- Add "Original" checkbox to CadConverter for comparing old vs new
- Store OriginalEntities on FileListItem to prevent tolerance creep
when re-running simplifier with different settings
Bend Detection:
- Propagate bend notes to collinear bend lines split by cutouts
using infinite-line perpendicular distance check
- Add bend note text rendering in EntityView at bend line midpoints
DXF Import:
- Fix trimmed ellipse closing chord: only close when sweep ≈ 2π,
preventing phantom lines through slot cutouts
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Use chars.Length instead of hardcoded 36 for modulus/division since
the character set excludes 0 and O. Pad with '2' (first valid char)
instead of '0' to avoid ambiguity.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Without this, simplified geometry was lost on file switch and
not included in the final GetDrawings output.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Add "Simplify..." button to the detail bar and wire up SimplifierViewerForm
as a tool window with lazy creation, positioning, and entity replacement on apply.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Foundation for the geometry simplifier that will replace consecutive line
segments with fitted arcs. Adds ArcCandidate data class, GeometrySimplifier
with stub Analyze/Apply methods, and FitCircle using the Kasa algebraic
least-squares method. Also adds InternalsVisibleTo for OpenNest.Tests on
OpenNest.Core.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
DxfImporter now filters ETCH entities (like BEND) since etch marks are
generated from bends during export, not cut geometry. GeometryOptimizer
no longer merges lines/arcs across different layers and preserves layer
and color on merged entities. EntityView draws etch marks directly from
the Bends list so they remain visible without relying on imported ETCH
entities.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Consolidate duplicated static methods (SplitFeatures, ComputeCutDistance,
IsFeatureEtch, feature ordering) from CincinnatiSheetWriter and
CincinnatiPartSubprogramWriter into a shared FeatureUtils class. Move
inline sub-program registry building from Post() into
CincinnatiPartSubprogramWriter.BuildRegistry().
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Wrap the left sidebar and right entity view in a SplitContainer so the
boundary can be dragged to resize. Fixed panel on the left with a 200px
minimum width.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
The remnant viewer previously always filtered by smallest part dimension,
hiding large remnants that were narrower than the smallest part. Added a
"Filter by part size" checkbox (on by default) so users can toggle this
off to see all remnants regardless of size.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Add toggleable pierce point drawing to PlateView that shows small red
filled circles at each rapid move endpoint (where cutting begins). Wire
through View menu, EditNestForm toggle, and MainForm handler.
Also rename RectangleShape/RoundedRectangleShape Width/Height to
Length/Width for consistency with CNC conventions, update MCP tools and
tests accordingly. Fix SplitDrawingForm designer layout ordering and
EntityView bend line selection styling.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
After splitting a drawing with a circular hole, CadConverterForm writes
the split piece to DXF and re-imports it. The circle (decomposed into
two semicircular arcs by DrawingSplitter) was being incorrectly merged
back into a single zero-sweep arc by GeometryOptimizer.TryJoinArcs
during reimport.
Root cause: TryJoinArcs mutated input arc angles in-place and didn't
guard against merging two arcs that together form a full circle. When
arc2 had startAngle=π, endAngle=0 (DXF wrap-around from 360°→0°), the
mutation produced startAngle=-π, and the merge created an arc with
startAngle=π, endAngle=π (zero sweep), losing half the hole.
Fix: use local variables instead of mutating inputs, require arcs to be
adjacent (endpoints touching) rather than just overlapping, and refuse
to merge when the combined sweep would be a full circle.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
FitToPlate now places split lines at usable-width intervals so each
piece (except the last) fills the entire plate work area. Also adds a
live yellow preview line that follows the cursor during manual split
line placement, and piece dimension labels in the preview regions.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
DrawingSplitter now clips bend lines to each piece's region using
Liang-Barsky line clipping and offsets them to the new origin. Bend
properties (direction, angle, radius, note text) are preserved through
the entire split pipeline instead of being lost during re-import.
CadConverterForm applies the same origin offset to bends before passing
them to the splitter, and creates FileListItems directly from split
results to avoid re-detection overwriting the bend metadata.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
- Change split file suffix from _split# to -# (e.g., PartName-1.dxf)
- Add numbered labels at the center of each split region in the preview
- Fix fit-to-plate axis calculation to use correct plate dimension
instead of min(width, height) for single-axis splits
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Replace sidebar Panel+Splitter with SplitContainer for resizable file
list / filter panel. Sort file list alphabetically on insert. Widen bend
line dash spacing and draw ETCH layer entities on top of bend lines so
etch marks are visible.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
BEND layer lines were being imported as cut geometry alongside the
separate Bend object detection, causing duplicate dark lines in nests.
Skip BEND layer entities in DxfImporter since bend detection reads
directly from the raw CadDocument.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
PushBoundingBox left exactly partSpacing between bounding boxes, but the
geometry push inflates offset lines by halfSpacing + chordTolerance per
side (totaling partSpacing + 2*chordTolerance). The 0.002 overlap caused
RayEdgeDistance to return MaxValue for negative t, making the nearest
obstacle invisible and allowing the part to push through it.
Subtract 2*ChordTolerance from the BB push distance so the gap is wide
enough for the offset geometry lines to remain non-overlapping.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Fire SelectedIndexChanged when the first item is added so the preview
loads automatically. Invalidate the file list after quantity changes so
the badge repaints immediately.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
ConvertProgram.ToGeometry() created entities without setting Color,
defaulting to Color.Empty (alpha=0). After ededc7b switched from
Pens.White to per-entity colors, these rendered fully transparent.
- Add explicit colors to all SpecialLayers (Cut=White, Rapid=Gray, etc.)
- Set entity Color from layer in ConvertProgram for lines, arcs, circles
- Add GetEntityPen fallback: treat Empty/alpha-0 as White
- Add bend line rendering and selection in EntityView/CadConverterForm
- Fix SolidWorksBendDetector MText formatting strip for bend notes
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
SplitContainer wasn't sizing children correctly. Switched to the same
Panel(Dock.Left) + Splitter + Fill pattern used by SplitDrawingForm,
with explicit Size on all controls.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Replace the old DataGridView+TabControl layout with a sidebar containing
FileListControl and FilterPanel on the left, and EntityView with a detail
bar on the right. Adds drag-and-drop support, thread-safe parallel file
import, bend detection integration, and split-to-DXF workflow.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
ajandClaude Opus 4.6