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>
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.
Plan Cutting refused ordinary filleted parts with "Native contact query is
numerically uncertain." Material capture checks every curve pair of a ring,
adjacent ones included. Where a line meets a tangent arc at their shared
vertex, rounding can drop the tangent root of the native line/circle
quadratic; the exact ray cast from the line's far end then reached the
vertex, which is already recorded as an endpoint contact, and was read as a
contact the native query missed. Rounded rectangles rotated off-axis were
refused 1037 times in 1080 before this change and 0 times after.
The exactness rays now stop short of a line endpoint the other curve already
contains (half-way from each end when both are contained), so together they
still cover every other point of the line and any unrecorded contact still
refuses. The native kernel and tolerances are unchanged.
Regressions: four tangent-fillet rings and a rotated filleted part planned
through CuttingPlanBatch (red before, green after); a line ending inside a
small circle's contact band stays uncertain in both directions. Mutations that
treat either endpoint as always contained, drop the start ray, or count
recorded endpoints as native contacts all fail.
Project Memory: 41880037
The delta review found two more ways the extent filter could skip a
check a native query would have flagged:
- Native line intersections accept points 0.00001 outside each line's
bounding box, so a lead 0.000003 from another part touched it while
their extents were 0.000003 apart, beyond the 1e-6 margin.
- Around a circle of radius 5e11, rounding let the native query count
a rapid at x = -0.00001 as touching although the circle's extent
started at x = 0; the margin scaled only with the rapid's own size.
Rather than chase each tolerance, the filter now has one narrow rule:
Extent.IsClearOf skips only when both extents are finite, lie within
1e6 and are more than 0.001 apart on some axis. 0.001 is ten times the
widest absolute band of any native contact query (the 0.00001 box
allowance and the 0.0001 contact reach of tiny arcs), and within 1e6
rounding stays far below it. Larger geometry is always checked in
full, as before the filter. Planning speed is unchanged (144-part grid
about 0.5-0.8 s).
All three reproductions are regression tests, with a test of the rule
itself.
IsSeparatedFrom promised that NaN bounds are never separated, but a
finite axis could still compare as separated when the other axis held
NaN. Program reading already refuses nonfinite coordinates, so no
public path was affected; the helper now checks every bound and the
margin are finite before comparing, which also covers the empty
extent of an incomplete material snapshot.
Review of the extent filter (bfe2e51) found it could skip checks the
native queries would have flagged. ContactAfterStart counts a point as
touching an arc while its squared distance from the centre is within
1e-8 x max(1, 2r) of r^2, which for small arcs reaches well past the
radius (up to 1e-4 as r -> 0), more than the filter's margin. A rapid
0.000002 outside a radius-0.001 circle lost its crossing, the pre-post
review lost the same finding, and a lead grazing a radius-0.003 circle
turned from an uncertain check into a clear one.
An arc's extent now uses that contact reach, computed from the same
slack expression as ContactAfterStart, so every point a native query
can count as contact lies inside it. The three cases above are
regression tests.
Every lead was checked against every placed part's material and every
rapid against every completed contour, so each check cost O(parts) and
planning a plate cost O(parts^2). Lead checks were 88% of planning time
on a 144-part grid.
LeadMaterialSnapshot and each completed contour now keep a conservative
extent (an arc counts as its whole supporting circle). A lead or rapid
skips material or a contour only when the extents are farther apart
than 1e-6 x (1 + coordinate size), far above the contact tolerance, so
results are unchanged: anything touching or closer still gets the full
native check. The rapid filter also applies to pre-post verification,
which shares ReleasedContourState.
New tests cover the cases just inside the skip: an arc lead and a
completed arc whose bulge reaches past their endpoints, and a lead and
a rapid that only touch another part's extent.
ajandClaude Opus 5.5