Check Overlaps dismissed a tiny clamp by the part's coarse material bounds
before the fine tolerance-free test ran, but that material is inscribed at
the 0.001 chord tolerance: real material in the sliver beyond a convex arc
(a short arc cap, a rotated crescent) lay outside those bounds and the clamp
read as clear. For clamps below the tolerance the bounds are widened by the
chord tolerance before rejecting.
PM 407f5eb7-329f-41e4-947e-64ad52aa4034 (review s6-delta3-review.md)
Circumscribing every arc holds all material along convex arcs but drops a
sliver along concave ones (a notch), so a tiny clamp 6e-7 into the material
beside a notch read as clear. Tiny-clamp checks now test the part flattened
both ways (all arcs inscribed, all arcs circumscribed): along any arc one of
the two holds the real material, so together they find every real overlap.
PM 407f5eb7-329f-41e4-947e-64ad52aa4034 (delta review s6-delta2-review.md)
Fine inscribed flattening still let a native arc cut 6.2e-7 into a 1e-5
clamp unseen: less than one chord's sag, so the layout check, interactive
fill and Check Overlaps all called it clear. Tiny-clamp checks now
circumscribe perimeter arcs and inscribe cutout arcs (lines stay exact), so
the polygons hold every bit of real material. Any real overlap is reported;
the cost is a possible report within the tolerance of an arc, never a false
clear. The analyzer builds the same polygons instead of a second
OverlapMaterial read.
PM 407f5eb7-329f-41e4-947e-64ad52aa4034 (delta review s6-delta-review.md)
The tolerance-free rectangle test was fed approximated material: the layout
check passed it the 1e-4-grid validation outline (a strip of real material
that wholly contains a 1e-5 clamp could vanish), and interactive fill and
the overlap check passed 0.001 inscribed arc chords (a clamp inside a disk
but outside its chords read as clear). All three now flatten the native
contours at a quarter of the clamp's smaller side, lines kept exact, so the
arc-chord sliver can never hold the clamp. Ordinary clamps are unchanged.
PM 407f5eb7-329f-41e4-947e-64ad52aa4034
Changing the nest defaults (Nest Info, Set as default, Edit Plate on an
empty sheet) left the editor's trailing empty sheet on the old size and
quadrant, so the writer's clamp-preserving empty-sheet rule saved it as a
stale extra sheet. PlateManager.ChangePlateDefaults wraps a defaults edit:
a trailing empty, cutoff-free sheet that exactly matched the old defaults
(and followed their rail with no removed clamps or explicit zones) takes the
new defaults; every other empty sheet keeps its configuration and is still
written.
PM cade6901-5f4a-4503-85bf-0ea681d9ca7f
Plate.RemovedClamps exposed a HashSet (and every untouched plate shared one
static empty HashSet), so a downcast could change one plate's removal state
or every plate's at once without re-resolving zones. It is now an
ImmutableHashSet.
PM 6ded8ac4-84fd-4e8b-9a3b-6f41e494542c item (e)
Plate.ClampRemovalMinutes multiplied every listed removed id by the
removal time, including ids the rail places beyond the sheet after a resize
or does not know at all. Only removed clamps the rail resolves on this sheet
are pulled, so only those add time; the ids themselves stay listed (C13).
PM 6ded8ac4-84fd-4e8b-9a3b-6f41e494542c item (a)
Collision.Check finds no overlap region for a clamp smaller than its
tolerance, so Check Overlaps reported a part covering a 1e-5 clamp as clear.
Clamps below 0.001 are judged with KeepOutOverlap and reported as a finding
whose fragment is the whole clamp rectangle; flush and clear parts stay clear.
PM aa995123-295f-479c-adc4-b0cbcb7cf838
D10 (user decision 2026-10-13, keep the warning): a clamp footprint covering
the modeled program start (0,0) makes the first rapid of every posting attempt
cross it, and that warning has no exemption and no persisted bypass. Lock the
behavior in all four quadrants with a physical-footprint oracle and a mutation
red (skipping rapids that start inside a zone reddens exactly the four
origin-covering rows). Document the design in docs/post-verification.md.
The desktop captures the overlap freshness stamp before its error
boundary, and a null cut-off or clamp zone in the plate's lists threw
NullReferenceException there. Stamp missing entries as a distinct empty
state so the whole-plate capture can report the malformed input as a
failed check instead.
Project Memory: opennest cdbe2629-b562-46ee-9509-2b120a511654
Pre-post clamp checks looked only at nominal cut-off definitions and
rapids. A definition moved without regenerating its placed program
left a cut through an active clamp that posted with no warning, because
cut-off material is excluded from the overlap check.
Also check each cut-off part's placed cutting motions against the
clamps in the placement frame (lines exactly, arcs by their extent).
Report one warning per cut-off part and clamp, so a current definition
does not produce a duplicate of its nominal finding.
Project Memory: opennest cdbe2629-b562-46ee-9509-2b120a511654
Plate.ClampZones are stored relative to the sheet's lower-left corner,
but cut-off positions, motions and part poses use the signed quadrant
frame. The automatic cutoff planner, manual cut-off contacts, clamp
rapid warnings and whole-plate overlap capture compared the two
directly, so in quadrants 2-4 a cut or rapid through a real rail clamp
was neither avoided nor warned about.
Add ClampZoneFrame.ToPlacement, which maps live zones into the
placement frame exactly like the sheet and engine stock, and use it in
every Slice 5 consumer. It rejects missing or malformed zones (bounds
stay publicly mutable); pre-post verification reports those as an
incomplete clamp check instead of a clear result. Overlap freshness now
treats a size or quadrant change as moving the zones.
Tests use real ClampRail zones in all quadrants; the hand-signed
quadrant fixtures that hid the defect are converted to rails.
Project Memory: opennest 274836d5-fb76-4619-b3cc-0c811e767dd6
The automatic cutoff planner tested only the proposed X against active
clamp spans, then certified a tolerance-close existing line at its own
X. A manual line just inside a clamp edge could therefore be reported
as a verified tail separator. Test the proposed X and every equivalent
existing definition before regenerating.
Also keep a same-line limited manual cut blocking the whole plan when
it lies on a clamp, as it did before clamp checks were added.
Project Memory: opennest 51597040-cff6-4304-87dc-3c2a13edf45a
Slice 3b task 3 (D9 + display). OpenNest.Core: TimingInfo gains
ClampRemovalMinutes (included in +, -, * so every aggregation stays
consistent); Timing.GetTimingInfo(Plate) adds plate.ClampRemovalMinutes
once per physical sheet, before the quantity multiply so it scales
with everything else cut on that sheet; CalculateTime adds it to the
estimate as a flat number of minutes regardless of the cut parameters'
unit. A plate with nothing removed is unaffected (zero).
OpenNest.Data: ClampSettings and ClampRailEditor carry RemovalMinutes
through the same three boundaries as clamp size - the rail/constructor,
the settings file (missing key falls back to
ClampRail.DefaultRemovalMinutes; present but negative/non-numeric/null
is ignored and reported Partial, same as width/depth), and
ToMachineDefaults - except it is a time, not a length, so
ConvertedTo never scales it between inches and millimeters.
Desktop: ClampsForm gets a 'Minutes to remove and replace one clamp'
field wired to the editor; PlateRenderer.DrawRemovedClamps draws each
clamp Plate.RemovedClamps lists (resolved from the full rail, since a
removed clamp is absent from Plate.ClampZones) as a dashed grey
outline with a small 'remove' marker, distinct from an active clamp's
solid hatch and still display-only - no hit test, selection or
sequencing; PlateView calls it right after the active-zone pass.
MainForm's Auto Nest completion flow lists every committed sheet with
a removal as 'Sheet N: remove clamp-X (+5 min)', using
Plate.RemovedClamps/ClampRemovalMinutes from Slice 3b tasks 1-2.
Tests: 10 new Data (ClampSettingsTests, ClampRailEditorTests) covering
round-trip/default/invalid-value handling and the never-scaled-by-units
rule; 4 new Core (TimingTests) covering the per-sheet add, the quantity
scaling, CalculateTime, and nest-level aggregation across plates.
Desktop changes (dialog field, renderer, Auto Nest summary) are
compile-verified only (-p:EnableWindowsTargeting=true), matching the
project's existing WinForms testing bar - no automated UI test exists
for the sibling DrawClampZones either.
Gates: Release OpenNest.Tests 3898 passed/31 skipped, OpenNest.IO.Tests
105 passed, OpenNest.Engine.Tests 878 passed/2 skipped; desktop and
OpenNest.WinForms.Tests cross-builds clean; scoped dotnet format
--verify-no-changes clean.
This completes Slice 3b (D8/D9) on top of Slice 3's rail-following
plates. Not published; master and other feature/clamp-zones-* branches
untouched. Windows runtime/visual acceptance not claimed - the plan's
click-through checklist (after slices 3-5) still applies.
Slice 3b task 1 (D8/D9): ClampRail gains RemovalMinutes (D9, default
5 minutes, validated finite >= 0) and Plate gains RemovedClamps (rail
clamp ids taken off this sheet as a last resort) plus the computed
ClampRemovalMinutes. Plate.SetClampRail gains an overload that
attaches a rail with a removed-clamp set; zones become the rail's
resolution for the sheet minus those ids, re-resolved on every
resize/rotate so a removed clamp stays off and reappears removed if a
later resize brings it back onto the sheet. ClampRail.Matches gains an
overload comparing against the reduced resolution.
IO: PlateDto.RemovedClamps and ClampRailDto.RemovalMinutes persist
(missing removalMinutes falls back to the default; missing
removedClamps means none). The writer's empty-plate drop logic no
longer drops a sheet whose only content is a removal state the
defaults can't recreate. The reader re-attaches the nest rail to a
plate only when its saved zones equal the rail's resolution minus its
saved removed ids, so a reduced-clamp sheet keeps following the rail
(and the removal) through later resizes instead of freezing as static
zones.
Engine/desktop wiring (minimal-removal computation, Auto Nest
last-resort removal, cut-time, UI) is Slice 3b tasks 2-3, not yet
done.
Tests: 16 new Core (ClampRailTests) + 5 new IO (ClampRailPersistenceTests)
covering validation, resize/resolve behavior, round-trip, legacy
missing-key defaults, and the empty-plate-with-removal-only retention
case. Mutation check (reverting the RemovedClamps subtraction) turns
3 Core + 2 IO assertions red, confirming real coverage.
Gates: Release OpenNest.Tests 3884 passed/31 skipped, OpenNest.IO.Tests
105 passed, OpenNest.Engine.Tests (Clamp filter) 98 passed; scoped
dotnet format --verify-no-changes clean.
A clamp is an avoidance area, so a clamp that only partly reaches a
sheet (for example centered at 60.5" on a 60" sheet, or near the
origin) now keeps its whole 1.5" x 0.625" footprint instead of being
clipped to the sheet; clamps wholly beyond the sheet are still left
off. Job validation accepts a zone that hangs past the sheet edges and
still rejects one that does not reach the sheet at all. Both packing
lanes already block keep-outs extending past the bin; a hanging-clamp
solve through Rectangles, Irregular and Default keeps every part clear
of the whole inflated footprint.
User decision 2026-10-12, settling the plan's pending D2 question.
Plan Cutting previews were built without the plate's clamp zones, so
machine clamps disappeared from the canvas while inspecting a proposal.
Copy the plate's immutable zones onto the detached preview; it does not
follow the rail, so it never re-resolves.
Review finding 8, Project Memory 4e5f566d.
Read clamps.json as a raw document so an explicit null is reported as
an ignored value (Partial, which the desktop warns about) instead of
being taken as an absent field. Missing or invalid sizes now fall back
to the physical 1.5 x 0.625 inch clamp expressed in the file's units,
so a millimeter file no longer gets a 1.5 x 0.625 mm clamp. Values that
would overflow when converted between inches and millimeters are
ignored and reported instead of throwing while creating a nest.
Review findings 2, 3 and 6, Project Memory 4e5f566d.
Enabled clamp settings give a new nest its rail; whole-job Auto Nest
through the template stock, validated pipeline and commit keeps every
part clear of the clamps (an independent box oracle grown by the bottom
edge spacing) on every sheet while still using the edge between them,
for Rectangles and Default in quadrant 1 and Rectangles in quadrant 3.
Save and reload keep the rail, each sheet's zones and placements, and
do not write the empty tail sheet.
New and BOM import give a new nest the machine clamp rail from
clamps.json when it is enabled, converted to the nest's units; with the
default (off) settings nests are created exactly as before. An
unreadable or partly invalid settings file warns once per session.
Nest > Clamps... edits the current nest's rail: clamp width and depth
and a sorted list of X centers with Add/Remove. OK applies the rail to
every plate (Cancel discards the edits); Load Machine Defaults only
fills the dialog; Save as Machine Defaults writes clamps.json at once
and is labelled as not undone by Cancel. The dialog refuses to open
while nesting or a plate action runs. Its decisions live in the
Linux-tested ClampRailEditor; the form only renders and forwards input.
PlateView draws clamp zones as translucent hatched amber rectangles
over the sheet and parts and repaints when they change. They take part
in no hit test, selection or sequencing.
Persist the machine clamp rail in %APPDATA%\OpenNest\clamps.json, in
the same shape as the nest defaults store: camelCase JSON written with
retry, and a read that never throws. Clamps are off by default: a
missing or unreadable file keeps them off, and nothing changes until
the settings are enabled with at least one center.
Each value is read independently; an invalid one (including a single
bad clamp center) is ignored and reported as Partial so the desktop
can warn that the rail may lack a physical clamp. Values carry their
units and convert between inches and millimeters for a new nest.
Add ClampRail: identical clamps (width along the edge, depth into the
sheet) at X centers measured from the plate origin on the origin-side
edge. It resolves onto any sheet size and quadrant without re-scaling:
clamps wholly beyond the sheet are skipped, one still reaching onto it
is clipped to it, and ids follow rail position (clamp-N) so a physical
clamp keeps its id on every sheet.
A plate can follow a rail (Plate.SetClampRail); its ClampZones are then
derived and re-resolved whenever Size or Quadrant changes, because the
clamps are fixed to the machine. Plates without a rail keep explicit
zones unchanged. Nest.PlateDefaults.ClampRail is the template new plates
follow, and Nest.SetClampRail applies a nest-wide rail to every plate
(an empty rail removes it).
Introduce ClampZone: an axis-aligned rectangular keep-out in plate
coordinates (id + detached Box), validated finite, positive-size and
identified. Plate.ClampZones is a first-class collection alongside
Parts/CutOffs with a ClampZonesChanged event for view refresh. Zones are
never parts: quantity, utilization, cut sequence and CNC output ignore
them (locked by tests); they carry no z-height reasoning.
Nests converted from another CAM system carry its seam overcut inside the
clean contour: the last cut runs on past the contour's own start along its
first cut, then a straight jog returns to the start. The ring then touches
itself at its seam, so neither the cutting planner nor the overlap analyzer
could certify it and the whole plate refused.
SeamOvercut recognizes exactly that shape (same line, or same circle and
direction) and trims it from an owned copy; the retraced tail encloses no
area, so material is unchanged and the drawing is never edited. Any other
self-contact still refuses. Arcs of one circle whose centers were each derived
from their own endpoints agree only within Epsilon, so their spans are now
compared at the seam tolerance: shared spans still refuse as overlap, while
arcs that only meet at a joint or lie apart no longer do.
Plates with parts nested in other parts' cutouts then failed to route, since
the host is cut last and every straight approach from the middle of a crowded
cutout crosses a finished neighbour. CuttingNestedOrder tours each host's
inner parts as one run ending beside the host's own contours, hosts follow
the parts beside them, and learned rules still win. Outside entries are
ordered by clear sight lines to the next cut, the look-ahead toward a host is
its nearest contour point rather than its centre, a cutout containing the
arrival point is routed from that point, and a pass that teaches an order
rule ends the round instead of repeating the blocked approach.
Tests: SeamOvercutTests and CuttingNestedOrderTests; the cutting-planning,
diagnostics and overlap tests in OpenNest.Tests pass (1023 passed, 6 skipped).
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
MaterialConfig only ever had one grade per material name, so the tree
and GetMaterial/GetParameters couldn't represent e.g. Mild Steel A36
vs. A1011 as distinct, independently-parameterized entries. Prep work
for an upcoming drawing database that will store material + grade per
drawing and needs to resolve cut parameters by that pair.
- MachineConfig gains GetMaterial(name, grade), GetGrades(name), and a
GetParameters(material, grade, thickness) overload, all keyed through
the existing SharedListNames normalization. The name-only overloads
stay for back-compat ("first grade found").
- MachineConfigForm's tree gains a real tier: Machine -> Material name
(synthetic grouping node) -> Grade -> Thickness. Add/remove gained
"Add Grade" and split "Delete Material" (all grades) from "Delete
Grade" (one entry). Renaming a grade's Name relocates its node to the
matching (or a new) group on focus-loss, keeping the tree in sync
without a full reload.
- No schema/JSON changes; existing machine files keep working as-is.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Report, dialog and diagnostic text across post verification, cutoff
planning, alignment and cutting-plan review repeatedly told the user
what checks weren't (safety certifications, proof, guarantees) instead
of what to do. Reworded these to state the same caveats affirmatively
(inspect X, confirm Y, review Z) without changing the underlying
safety guidance, and updated the tests/docs that pinned the old wording.
Point-in-material used exact Y comparisons, but rings are only nominally
closed: capture admits closure seams and PEP-converted or rotated geometry
carries sub-micro-inch vertex jogs. When a jog straddled the test ray's Y,
the two edges at that shared vertex disagreed which side it was on and the
parity flipped, so a point ten inches outside a material read as interior.
LeadMaterialSnapshot reported leads as entering a neighbour they could not
touch, and the enclosing-perimeter check refused to capture materials whose
rings it misclassified.
Snap the ray comparison by the admitted seam tolerance so both edges at a
shared vertex decide together. Features larger than the tolerance still
count, and containment of a point within the tolerance of an edge stays as
ambiguous as before. On the 93-plate corpus 83 plates are untouched, one
previously refused plate now plans and replays, and 48/93 plates reach
Ready. Accepting more leads also changed one plate's first-found route to a
longer rapid path; that is search ranking, recorded with the measurements.
Also drops an extent-prefilter fast path measured at -6.8% corpus time: it
cleared leads whose native contact was reported beyond any fixed bbox
margin, which NearbyMaterialCheckTests deliberately pins as a refusal.
Capture and preparation agree that a nominal contour may close within
NominalContourClosure.Tolerance inclusively, which converted drawings rely on:
the sampled production corpus carries vertex gaps up to 1e-6. Replay
verification still compared those rings at the exact geometry epsilon, so the
one joint a rotated tool path legitimately bridges refused the whole plate
after the search had already spent its budget.
Census of 91 plates from 60 stored nests: every searched plate containing such
a seam refused with contour-accounting (4 plates, 76.5s of wasted search, worst
71.7s for one 11-part plate), and none of the 42 ready plates had one. Replay
now carries that same admitted endpoint gap as positional and length slack for
the affected ring only. Direction sign, coverage order, retrace detection, ring
counting and selected-emission binding keep the exact epsilon, and capture's
closure admission is unchanged.
With the fix the census yields 45 ready plates instead of 42, no plate changed
any other way, and expansion counts are identical wherever status matched.
P260805-01's 16-part plate plans in 0.76s rather than refusing after 4,129
expansions.
Tests: SeamClosureReplayTests covers seams of 0, 5e-7 and 1e-6 plus four
accounting faults (missing edge, reversed edge, interior shift beyond the
admitted seam, second circuit) that must still refuse, and the beyond-tolerance
capture refusal. OpenNest.Tests 3751, OpenNest.Engine.Tests 690 and
OpenNest.IO.Tests 79 pass; Windows-only projects cannot build on Linux.
aj
