fix: update PlateView fill path and sync stats with preview

- Route best-result updates to progress form preview in
  PlateView.FillWithProgress (Ctrl+F path) — was still using
  the old SetStationaryParts approach
- Only update results stats (parts, density, area) when
  IsOverallBest so they match the preview display

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

CLAUDE.md

@@ -25,7 +25,7 @@ Domain model, geometry, and CNC primitives organized into namespaces:
 
 - **Root** (`namespace OpenNest`): Domain model — `Nest` → `Plate[]` → `Part[]` → `Drawing` → `Program`. A `Nest` is the top-level container. Each `Plate` has a size, material, quadrant, spacing, and contains placed `Part` instances. Each `Part` references a `Drawing` (the template) and has its own location/rotation. A `Drawing` wraps a CNC `Program`. Also contains utilities: `PartGeometry`, `Align`, `Sequence`, `Timing`.
 - **CNC** (`CNC/`, `namespace OpenNest.CNC`): `Program` holds a list of `ICode` instructions (G-code-like: `RapidMove`, `LinearMove`, `ArcMove`, `SubProgramCall`). Programs support absolute/incremental mode conversion, rotation, offset, bounding box calculation, and cloning.
-- **Geometry** (`Geometry/`, `namespace OpenNest.Geometry`): Spatial primitives (`Vector`, `Box`, `Size`, `Spacing`, `BoundingBox`, `IBoundable`) and higher-level shapes (`Line`, `Arc`, `Circle`, `Polygon`, `Shape`) used for intersection detection, area calculation, and DXF conversion. Also contains `Intersect` (intersection algorithms), `ShapeBuilder` (entity chaining), `GeometryOptimizer` (line/arc merging), `SpatialQuery` (directional distance, ray casting, box queries), `ShapeProfile` (perimeter/area analysis), `NoFitPolygon`, `InnerFitPolygon`, `ConvexHull`, `ConvexDecomposition`, and `RotatingCalipers`.
+- **Geometry** (`Geometry/`, `namespace OpenNest.Geometry`): Spatial primitives (`Vector`, `Box`, `Size`, `Spacing`, `BoundingBox`, `IBoundable`) and higher-level shapes (`Line`, `Arc`, `Circle`, `Polygon`, `Shape`) used for intersection detection, area calculation, and DXF conversion. Also contains `Intersect` (intersection algorithms), `ShapeBuilder` (entity chaining), `GeometryOptimizer` (line/arc merging), `SpatialQuery` (directional distance, ray casting, box queries), `ShapeProfile` (perimeter/area analysis), `NoFitPolygon`, `InnerFitPolygon`, `ConvexHull`, `ConvexDecomposition`, `RotatingCalipers`, and `Collision` (overlap detection with Sutherland-Hodgman polygon clipping and hole subtraction).
 - **Converters** (`Converters/`, `namespace OpenNest.Converters`): Bridges between CNC and Geometry — `ConvertProgram` (CNC→Geometry), `ConvertGeometry` (Geometry→CNC), `ConvertMode` (absolute↔incremental).
 - **Math** (`Math/`, `namespace OpenNest.Math`): `Angle` (radian/degree conversion), `Tolerance` (floating-point comparison), `Trigonometry`, `Generic` (swap utility), `EvenOdd`, `Rounding` (factor-based rounding). Note: `OpenNest.Math` shadows `System.Math` — use `System.Math` fully qualified where both are needed.
 - **CNC/CuttingStrategy** (`CNC/CuttingStrategy/`, `namespace OpenNest.CNC`): `ContourCuttingStrategy` orchestrates cut ordering, lead-ins/lead-outs, and tabs. Includes `LeadIn`/`LeadOut` hierarchies (line, arc, clean-hole variants), `Tab` hierarchy (normal, machine, breaker), and `CuttingParameters`/`AssignmentParameters`/`SequenceParameters` configuration.

OpenNest.Core/Align.cs

@@ -125,61 +125,36 @@ namespace OpenNest
             parts.ForEach(part => Bottom(fixedPart, part));
         }
 
-        public static void EvenlyDistributeHorizontally(List<Part> parts)
+        public static void EvenlyDistributeHorizontally(List<Part> parts) =>
+            EvenlyDistribute(parts, horizontal: true);
+
+        public static void EvenlyDistributeVertically(List<Part> parts) =>
+            EvenlyDistribute(parts, horizontal: false);
+
+        private static void EvenlyDistribute(List<Part> parts, bool horizontal)
         {
             if (parts.Count < 3)
                 return;
 
             var list = new List<Part>(parts);
-            list.Sort((p1, p2) => p1.BoundingBox.Center.X.CompareTo(p2.BoundingBox.Center.X));
+            list.Sort((p1, p2) => horizontal
+                ? p1.BoundingBox.Center.X.CompareTo(p2.BoundingBox.Center.X)
+                : p1.BoundingBox.Center.Y.CompareTo(p2.BoundingBox.Center.Y));
 
             var lastIndex = list.Count - 1;
 
-            var first = list[0];
-            var last = list[lastIndex];
+            var start = horizontal ? list[0].BoundingBox.Center.X : list[0].BoundingBox.Center.Y;
+            var end = horizontal ? list[lastIndex].BoundingBox.Center.X : list[lastIndex].BoundingBox.Center.Y;
 
-            var start = first.BoundingBox.Center.X;
-            var end = last.BoundingBox.Center.X;
-            var diff = end - start;
+            var spacing = (end - start) / lastIndex;
 
-            var spacing = diff / lastIndex;
-
-            for (int i = 1; i < lastIndex; ++i)
+            for (var i = 1; i < lastIndex; ++i)
             {
                 var part = list[i];
-                var newX = start + i * spacing;
-                var curX = part.BoundingBox.Center.X;
+                var cur = horizontal ? part.BoundingBox.Center.X : part.BoundingBox.Center.Y;
+                var delta = start + i * spacing - cur;
 
-                part.Offset(newX - curX, 0);
-            }
-        }
-
-        public static void EvenlyDistributeVertically(List<Part> parts)
-        {
-            if (parts.Count < 3)
-                return;
-
-            var list = new List<Part>(parts);
-            list.Sort((p1, p2) => p1.BoundingBox.Center.Y.CompareTo(p2.BoundingBox.Center.Y));
-
-            var lastIndex = list.Count - 1;
-
-            var first = list[0];
-            var last = list[lastIndex];
-
-            var start = first.BoundingBox.Center.Y;
-            var end = last.BoundingBox.Center.Y;
-            var diff = end - start;
-
-            var spacing = diff / lastIndex;
-
-            for (int i = 1; i < lastIndex; ++i)
-            {
-                var part = list[i];
-                var newX = start + i * spacing;
-                var curX = part.BoundingBox.Center.Y;
-
-                part.Offset(0, newX - curX);
+                part.Offset(horizontal ? delta : 0, horizontal ? 0 : delta);
             }
         }
     }

OpenNest.Core/CNC/Program.cs

@@ -51,37 +51,7 @@ namespace OpenNest.CNC
             mode = Mode.Absolute;
         }
 
-        public virtual void Rotate(double angle)
-        {
-            var mode = Mode;
-
-            SetModeAbs();
-
-            for (int i = 0; i < Codes.Count; ++i)
-            {
-                var code = Codes[i];
-
-                if (code.Type == CodeType.SubProgramCall)
-                {
-                    var subpgm = (SubProgramCall)code;
-
-                    if (subpgm.Program != null)
-                        subpgm.Program.Rotate(angle);
-                }
-
-                if (code is Motion == false)
-                    continue;
-
-                var code2 = (Motion)code;
-
-                code2.Rotate(angle);
-            }
-
-            if (mode == Mode.Incremental)
-                SetModeInc();
-
-            Rotation = Angle.NormalizeRad(Rotation + angle);
-        }
+        public virtual void Rotate(double angle) => Rotate(angle, new Vector(0, 0));
 
         public override string ToString()
         {

OpenNest.Core/Geometry/ArcFit.cs

@@ -0,0 +1,76 @@
+using System.Collections.Generic;
+
+namespace OpenNest.Geometry
+{
+    /// <summary>
+    /// Shared arc-fitting utilities used by SplineConverter and GeometrySimplifier.
+    /// </summary>
+    internal static class ArcFit
+    {
+        /// <summary>
+        /// Fits a circular arc constrained to be tangent to the given direction at the
+        /// first point. The center lies at the intersection of the normal at P1 (perpendicular
+        /// to the tangent) and the perpendicular bisector of the chord P1->Pn, guaranteeing
+        /// the arc passes through both endpoints and departs P1 in the given direction.
+        /// </summary>
+        internal static (Vector center, double radius, double deviation) FitWithStartTangent(
+            List<Vector> points, Vector tangent)
+        {
+            if (points.Count < 3)
+                return (Vector.Invalid, 0, double.MaxValue);
+
+            var p1 = points[0];
+            var pn = points[^1];
+
+            var mx = (p1.X + pn.X) / 2;
+            var my = (p1.Y + pn.Y) / 2;
+            var dx = pn.X - p1.X;
+            var dy = pn.Y - p1.Y;
+            var chordLen = System.Math.Sqrt(dx * dx + dy * dy);
+            if (chordLen < 1e-10)
+                return (Vector.Invalid, 0, double.MaxValue);
+
+            var bx = -dy / chordLen;
+            var by = dx / chordLen;
+
+            var tLen = System.Math.Sqrt(tangent.X * tangent.X + tangent.Y * tangent.Y);
+            if (tLen < 1e-10)
+                return (Vector.Invalid, 0, double.MaxValue);
+
+            var nx = -tangent.Y / tLen;
+            var ny = tangent.X / tLen;
+
+            var det = nx * by - ny * bx;
+            if (System.Math.Abs(det) < 1e-10)
+                return (Vector.Invalid, 0, double.MaxValue);
+
+            var s = ((mx - p1.X) * by - (my - p1.Y) * bx) / det;
+
+            var cx = p1.X + s * nx;
+            var cy = p1.Y + s * ny;
+            var radius = System.Math.Sqrt((cx - p1.X) * (cx - p1.X) + (cy - p1.Y) * (cy - p1.Y));
+
+            if (radius < 1e-10)
+                return (Vector.Invalid, 0, double.MaxValue);
+
+            return (new Vector(cx, cy), radius, MaxRadialDeviation(points, cx, cy, radius));
+        }
+
+        /// <summary>
+        /// Computes the maximum radial deviation of interior points from a circle.
+        /// </summary>
+        internal static double MaxRadialDeviation(List<Vector> points, double cx, double cy, double radius)
+        {
+            var maxDev = 0.0;
+            for (var i = 1; i < points.Count - 1; i++)
+            {
+                var px = points[i].X - cx;
+                var py = points[i].Y - cy;
+                var dist = System.Math.Sqrt(px * px + py * py);
+                var dev = System.Math.Abs(dist - radius);
+                if (dev > maxDev) maxDev = dev;
+            }
+            return maxDev;
+        }
+    }
+}

OpenNest.Core/Geometry/Collision.cs

@@ -0,0 +1,330 @@
+using OpenNest.Math;
+using System.Collections.Generic;
+
+namespace OpenNest.Geometry
+{
+    public static class Collision
+    {
+        public static CollisionResult Check(Polygon a, Polygon b,
+            List<Polygon> holesA = null, List<Polygon> holesB = null)
+        {
+            // Step 1: Bounding box pre-filter
+            if (!BoundingBoxesOverlap(a.BoundingBox, b.BoundingBox))
+                return CollisionResult.None;
+
+            // Step 2: Quick intersection test for crossing points
+            var intersectionPoints = FindCrossingPoints(a, b);
+
+            // Step 3: Convex decomposition
+            var trisA = TriangulateWithBounds(a);
+            var trisB = TriangulateWithBounds(b);
+
+            // Step 4: Clip all triangle pairs
+            var regions = new List<Polygon>();
+
+            foreach (var triA in trisA)
+            {
+                foreach (var triB in trisB)
+                {
+                    if (!BoundingBoxesOverlap(triA.BoundingBox, triB.BoundingBox))
+                        continue;
+
+                    var clipped = ClipConvex(triA, triB);
+                    if (clipped != null)
+                        regions.Add(clipped);
+                }
+            }
+
+            // Step 5: Hole subtraction
+            if (regions.Count > 0)
+                regions = SubtractHoles(regions, holesA, holesB);
+
+            if (regions.Count == 0)
+                return new CollisionResult(false, regions, intersectionPoints);
+
+            // Step 6: Build result
+            return new CollisionResult(true, regions, intersectionPoints);
+        }
+
+        public static bool HasOverlap(Polygon a, Polygon b,
+            List<Polygon> holesA = null, List<Polygon> holesB = null)
+        {
+            if (!BoundingBoxesOverlap(a.BoundingBox, b.BoundingBox))
+                return false;
+
+            // Full check is needed: crossing points alone miss containment cases
+            // (one polygon entirely inside another has zero edge crossings).
+            return Check(a, b, holesA, holesB).Overlaps;
+        }
+
+        public static List<CollisionResult> CheckAll(List<Polygon> polygons,
+            List<List<Polygon>> holes = null)
+        {
+            var results = new List<CollisionResult>();
+
+            for (var i = 0; i < polygons.Count; i++)
+            {
+                for (var j = i + 1; j < polygons.Count; j++)
+                {
+                    var holesA = holes != null && i < holes.Count ? holes[i] : null;
+                    var holesB = holes != null && j < holes.Count ? holes[j] : null;
+                    var result = Check(polygons[i], polygons[j], holesA, holesB);
+
+                    if (result.Overlaps)
+                        results.Add(result);
+                }
+            }
+
+            return results;
+        }
+
+        public static bool HasAnyOverlap(List<Polygon> polygons,
+            List<List<Polygon>> holes = null)
+        {
+            for (var i = 0; i < polygons.Count; i++)
+            {
+                for (var j = i + 1; j < polygons.Count; j++)
+                {
+                    var holesA = holes != null && i < holes.Count ? holes[i] : null;
+                    var holesB = holes != null && j < holes.Count ? holes[j] : null;
+
+                    if (HasOverlap(polygons[i], polygons[j], holesA, holesB))
+                        return true;
+                }
+            }
+
+            return false;
+        }
+
+        private static bool BoundingBoxesOverlap(Box a, Box b)
+        {
+            var overlapX = System.Math.Min(a.Right, b.Right)
+                         - System.Math.Max(a.Left, b.Left);
+            var overlapY = System.Math.Min(a.Top, b.Top)
+                         - System.Math.Max(a.Bottom, b.Bottom);
+
+            return overlapX > Tolerance.Epsilon && overlapY > Tolerance.Epsilon;
+        }
+
+        private static List<Vector> FindCrossingPoints(Polygon a, Polygon b)
+        {
+            if (!Intersect.Intersects(a, b, out var rawPts))
+                return new List<Vector>();
+
+            // Filter boundary contacts (vertex touches)
+            var vertsA = CollectVertices(a);
+            var vertsB = CollectVertices(b);
+            var filtered = new List<Vector>();
+
+            foreach (var pt in rawPts)
+            {
+                if (IsNearAnyVertex(pt, vertsA) || IsNearAnyVertex(pt, vertsB))
+                    continue;
+                filtered.Add(pt);
+            }
+
+            return filtered;
+        }
+
+        private static List<Vector> CollectVertices(Polygon polygon)
+        {
+            var verts = new List<Vector>(polygon.Vertices.Count);
+            foreach (var v in polygon.Vertices)
+                verts.Add(v);
+            return verts;
+        }
+
+        private static bool IsNearAnyVertex(Vector pt, List<Vector> vertices)
+        {
+            foreach (var v in vertices)
+            {
+                if (pt.X.IsEqualTo(v.X) && pt.Y.IsEqualTo(v.Y))
+                    return true;
+            }
+            return false;
+        }
+
+        /// <summary>
+        /// Triangulates a polygon and ensures each triangle has its bounding box updated.
+        /// </summary>
+        private static List<Polygon> TriangulateWithBounds(Polygon polygon)
+        {
+            var tris = ConvexDecomposition.Triangulate(polygon);
+            foreach (var tri in tris)
+                tri.UpdateBounds();
+            return tris;
+        }
+
+        /// <summary>
+        /// Sutherland-Hodgman polygon clipping. Clips subject against each edge
+        /// of clip. Both must be convex. Returns null if no overlap.
+        /// </summary>
+        private static Polygon ClipConvex(Polygon subject, Polygon clip)
+        {
+            var output = new List<Vector>(subject.Vertices);
+
+            // Remove closing vertex if present
+            if (output.Count > 1 && output[0].X == output[output.Count - 1].X
+                                  && output[0].Y == output[output.Count - 1].Y)
+                output.RemoveAt(output.Count - 1);
+
+            var clipVerts = new List<Vector>(clip.Vertices);
+            if (clipVerts.Count > 1 && clipVerts[0].X == clipVerts[clipVerts.Count - 1].X
+                                     && clipVerts[0].Y == clipVerts[clipVerts.Count - 1].Y)
+                clipVerts.RemoveAt(clipVerts.Count - 1);
+
+            for (var i = 0; i < clipVerts.Count; i++)
+            {
+                if (output.Count == 0)
+                    return null;
+
+                var edgeStart = clipVerts[i];
+                var edgeEnd = clipVerts[(i + 1) % clipVerts.Count];
+                var input = output;
+                output = new List<Vector>();
+
+                for (var j = 0; j < input.Count; j++)
+                {
+                    var current = input[j];
+                    var next = input[(j + 1) % input.Count];
+                    var currentInside = Cross(edgeStart, edgeEnd, current) >= -Tolerance.Epsilon;
+                    var nextInside = Cross(edgeStart, edgeEnd, next) >= -Tolerance.Epsilon;
+
+                    if (currentInside)
+                    {
+                        output.Add(current);
+                        if (!nextInside)
+                        {
+                            var ix = LineIntersection(edgeStart, edgeEnd, current, next);
+                            if (ix.IsValid())
+                                output.Add(ix);
+                        }
+                    }
+                    else if (nextInside)
+                    {
+                        var ix = LineIntersection(edgeStart, edgeEnd, current, next);
+                        if (ix.IsValid())
+                            output.Add(ix);
+                    }
+                }
+            }
+
+            if (output.Count < 3)
+                return null;
+
+            var result = new Polygon();
+            result.Vertices.AddRange(output);
+            result.Close();
+            result.UpdateBounds();
+
+            // Reject degenerate slivers
+            if (result.Area() < Tolerance.Epsilon)
+                return null;
+
+            return result;
+        }
+
+        /// <summary>
+        /// Cross product of vectors (edgeStart->edgeEnd) and (edgeStart->point).
+        /// Positive = point is left of edge (inside for CCW polygon).
+        /// </summary>
+        private static double Cross(Vector edgeStart, Vector edgeEnd, Vector point)
+        {
+            return (edgeEnd.X - edgeStart.X) * (point.Y - edgeStart.Y)
+                 - (edgeEnd.Y - edgeStart.Y) * (point.X - edgeStart.X);
+        }
+
+        /// <summary>
+        /// Intersection of lines (a1->a2) and (b1->b2). Returns Vector.Invalid if parallel.
+        /// </summary>
+        private static Vector LineIntersection(Vector a1, Vector a2, Vector b1, Vector b2)
+        {
+            var d1x = a2.X - a1.X;
+            var d1y = a2.Y - a1.Y;
+            var d2x = b2.X - b1.X;
+            var d2y = b2.Y - b1.Y;
+            var cross = d1x * d2y - d1y * d2x;
+
+            if (System.Math.Abs(cross) < Tolerance.Epsilon)
+                return Vector.Invalid;
+
+            var t = ((b1.X - a1.X) * d2y - (b1.Y - a1.Y) * d2x) / cross;
+            return new Vector(a1.X + t * d1x, a1.Y + t * d1y);
+        }
+
+        /// <summary>
+        /// Subtracts holes from overlap regions.
+        /// </summary>
+        private static List<Polygon> SubtractHoles(List<Polygon> regions,
+            List<Polygon> holesA, List<Polygon> holesB)
+        {
+            var allHoles = new List<Polygon>();
+            if (holesA != null) allHoles.AddRange(holesA);
+            if (holesB != null) allHoles.AddRange(holesB);
+
+            if (allHoles.Count == 0)
+                return regions;
+
+            foreach (var hole in allHoles)
+            {
+                var holeTris = TriangulateWithBounds(hole);
+                var surviving = new List<Polygon>();
+
+                foreach (var region in regions)
+                {
+                    var pieces = SubtractTriangles(region, holeTris);
+                    surviving.AddRange(pieces);
+                }
+
+                regions = surviving;
+
+                if (regions.Count == 0)
+                    break;
+            }
+
+            return regions;
+        }
+
+        /// <summary>
+        /// Subtracts hole triangles from a region. Conservative: partial overlaps
+        /// keep the full piece triangle (acceptable for visual shading).
+        /// </summary>
+        private static List<Polygon> SubtractTriangles(Polygon region, List<Polygon> holeTris)
+        {
+            var current = new List<Polygon> { region };
+
+            foreach (var holeTri in holeTris)
+            {
+                if (!BoundingBoxesOverlap(region.BoundingBox, holeTri.BoundingBox))
+                    continue;
+
+                var next = new List<Polygon>();
+
+                foreach (var piece in current)
+                {
+                    var pieceTris = TriangulateWithBounds(piece);
+
+                    foreach (var pieceTri in pieceTris)
+                    {
+                        var inside = ClipConvex(pieceTri, holeTri);
+                        if (inside == null)
+                        {
+                            // No overlap with hole - keep
+                            next.Add(pieceTri);
+                        }
+                        else if (inside.Area() < pieceTri.Area() - Tolerance.Epsilon)
+                        {
+                            // Partial overlap - keep the piece (conservative)
+                            next.Add(pieceTri);
+                        }
+                        // else: fully inside hole - discard
+                    }
+                }
+
+                current = next;
+            }
+
+            return current;
+        }
+    }
+}

OpenNest.Core/Geometry/CollisionResult.cs

@@ -0,0 +1,23 @@
+using System.Collections.Generic;
+using System.Linq;
+
+namespace OpenNest.Geometry
+{
+    public class CollisionResult
+    {
+        public static readonly CollisionResult None = new(false, new List<Polygon>(), new List<Vector>());
+
+        public CollisionResult(bool overlaps, List<Polygon> overlapRegions, List<Vector> intersectionPoints)
+        {
+            Overlaps = overlaps;
+            OverlapRegions = overlapRegions;
+            IntersectionPoints = intersectionPoints;
+            OverlapArea = overlapRegions.Sum(r => r.Area());
+        }
+
+        public bool Overlaps { get; }
+        public IReadOnlyList<Polygon> OverlapRegions { get; }
+        public IReadOnlyList<Vector> IntersectionPoints { get; }
+        public double OverlapArea { get; }
+    }
+}

OpenNest.Core/Geometry/EllipseConverter.cs

@@ -64,6 +64,25 @@ namespace OpenNest.Geometry
             return new Vector(p1.X + s * n1.X, p1.Y + s * n1.Y);
         }
 
+        internal static Vector Circumcenter(Vector a, Vector b, Vector c)
+        {
+            var ax = a.X - c.X;
+            var ay = a.Y - c.Y;
+            var bx = b.X - c.X;
+            var by = b.Y - c.Y;
+            var D = 2.0 * (ax * by - ay * bx);
+
+            if (System.Math.Abs(D) < 1e-10)
+                return Vector.Invalid;
+
+            var a2 = ax * ax + ay * ay;
+            var b2 = bx * bx + by * by;
+            var ux = (by * a2 - ay * b2) / D;
+            var uy = (ax * b2 - bx * a2) / D;
+
+            return new Vector(ux + c.X, uy + c.Y);
+        }
+
         public static List<Entity> Convert(Vector center, double semiMajor, double semiMinor,
             double rotation, double startParam, double endParam, double tolerance = 0.001)
         {
@@ -185,11 +204,20 @@ namespace OpenNest.Geometry
         {
             var p0 = EvaluatePoint(semiMajor, semiMinor, rotation, ellipseCenter, t0);
             var p1 = EvaluatePoint(semiMajor, semiMinor, rotation, ellipseCenter, t1);
+            var pMid = EvaluatePoint(semiMajor, semiMinor, rotation, ellipseCenter, (t0 + t1) / 2);
+
+            // Use circumcircle of (p0, pMid, p1) so the arc passes through both
+            // endpoints exactly, eliminating gaps between adjacent arcs.
+            var cc = Circumcenter(p0, pMid, p1);
+            if (cc.IsValid())
+            {
+                arcCenter = cc;
+                radius = p0.DistanceTo(cc);
+            }
 
             var startAngle = System.Math.Atan2(p0.Y - arcCenter.Y, p0.X - arcCenter.X);
             var endAngle = System.Math.Atan2(p1.Y - arcCenter.Y, p1.X - arcCenter.X);
 
-            var pMid = EvaluatePoint(semiMajor, semiMinor, rotation, ellipseCenter, (t0 + t1) / 2);
             var points = new List<Vector> { p0, pMid, p1 };
             var isReversed = SumSignedAngles(arcCenter, points) < 0;
 

OpenNest.Core/Geometry/GeometryOptimizer.cs

@@ -7,65 +7,46 @@ namespace OpenNest.Geometry
 {
     public static class GeometryOptimizer
     {
-        public static void Optimize(IList<Arc> arcs)
+        public static void Optimize(IList<Arc> arcs) =>
+            MergePass(arcs,
+                (list, item, i) => list.GetCoradialArs(item, i),
+                (Arc a, Arc b, out Arc joined) => TryJoinArcs(a, b, out joined));
+
+        public static void Optimize(IList<Line> lines) =>
+            MergePass(lines,
+                (list, item, i) => list.GetCollinearLines(item, i),
+                (Line a, Line b, out Line joined) => TryJoinLines(a, b, out joined));
+
+        private delegate bool TryJoin<T>(T a, T b, out T joined);
+
+        private static void MergePass<T>(IList<T> items,
+            Func<IList<T>, T, int, List<T>> findCandidates,
+            TryJoin<T> tryJoin) where T : class
         {
-            for (int i = 0; i < arcs.Count; ++i)
+            for (var i = 0; i < items.Count; ++i)
             {
-                var arc = arcs[i];
-
-                var coradialArcs = arcs.GetCoradialArs(arc, i);
-                int index = 0;
-
-                while (index < coradialArcs.Count)
-                {
-                    Arc arc2 = coradialArcs[index];
-                    Arc joinArc;
-
-                    if (!TryJoinArcs(arc, arc2, out joinArc))
-                    {
-                        index++;
-                        continue;
-                    }
-
-                    coradialArcs.Remove(arc2);
-                    arcs.Remove(arc2);
-
-                    arc = joinArc;
-                    index = 0;
-                }
-
-                arcs[i] = arc;
-            }
-        }
-
-        public static void Optimize(IList<Line> lines)
-        {
-            for (int i = 0; i < lines.Count; ++i)
-            {
-                var line = lines[i];
-
-                var collinearLines = lines.GetCollinearLines(line, i);
+                var item = items[i];
+                var candidates = findCandidates(items, item, i);
                 var index = 0;
 
-                while (index < collinearLines.Count)
+                while (index < candidates.Count)
                 {
-                    Line line2 = collinearLines[index];
-                    Line joinLine;
+                    var candidate = candidates[index];
 
-                    if (!TryJoinLines(line, line2, out joinLine))
+                    if (!tryJoin(item, candidate, out var joined))
                     {
                         index++;
                         continue;
                     }
 
-                    collinearLines.Remove(line2);
-                    lines.Remove(line2);
+                    candidates.Remove(candidate);
+                    items.Remove(candidate);
 
-                    line = joinLine;
+                    item = joined;
                     index = 0;
                 }
 
-                lines[i] = line;
+                items[i] = item;
             }
         }
 

OpenNest.Core/Geometry/GeometrySimplifier.cs

@@ -437,47 +437,8 @@ public class GeometrySimplifier
     /// the arc passes through both endpoints and departs P1 in the given direction.
     /// </summary>
     private static (Vector center, double radius, double deviation) FitWithStartTangent(
-        List<Vector> points, Vector tangent)
-    {
-        if (points.Count < 3)
-            return (Vector.Invalid, 0, double.MaxValue);
-
-        var p1 = points[0];
-        var pn = points[^1];
-
-        var mx = (p1.X + pn.X) / 2;
-        var my = (p1.Y + pn.Y) / 2;
-        var dx = pn.X - p1.X;
-        var dy = pn.Y - p1.Y;
-        var chordLen = System.Math.Sqrt(dx * dx + dy * dy);
-        if (chordLen < 1e-10)
-            return (Vector.Invalid, 0, double.MaxValue);
-
-        var bx = -dy / chordLen;
-        var by = dx / chordLen;
-
-        var tLen = System.Math.Sqrt(tangent.X * tangent.X + tangent.Y * tangent.Y);
-        if (tLen < 1e-10)
-            return (Vector.Invalid, 0, double.MaxValue);
-
-        var nx = -tangent.Y / tLen;
-        var ny = tangent.X / tLen;
-
-        var det = nx * by - ny * bx;
-        if (System.Math.Abs(det) < 1e-10)
-            return (Vector.Invalid, 0, double.MaxValue);
-
-        var t = ((mx - p1.X) * by - (my - p1.Y) * bx) / det;
-
-        var cx = p1.X + t * nx;
-        var cy = p1.Y + t * ny;
-        var radius = System.Math.Sqrt((cx - p1.X) * (cx - p1.X) + (cy - p1.Y) * (cy - p1.Y));
-
-        if (radius < 1e-10)
-            return (Vector.Invalid, 0, double.MaxValue);
-
-        return (new Vector(cx, cy), radius, MaxRadialDeviation(points, cx, cy, radius));
-    }
+        List<Vector> points, Vector tangent) =>
+        ArcFit.FitWithStartTangent(points, tangent);
 
     /// <summary>
     /// Computes the tangent direction at the last point of a fitted arc,
@@ -629,19 +590,8 @@ public class GeometrySimplifier
     /// <summary>
     /// Max deviation of intermediate points (excluding endpoints) from a circle.
     /// </summary>
-    private static double MaxRadialDeviation(List<Vector> points, double cx, double cy, double radius)
-    {
-        var maxDev = 0.0;
-        for (var i = 1; i < points.Count - 1; i++)
-        {
-            var px = points[i].X - cx;
-            var py = points[i].Y - cy;
-            var dist = System.Math.Sqrt(px * px + py * py);
-            var dev = System.Math.Abs(dist - radius);
-            if (dev > maxDev) maxDev = dev;
-        }
-        return maxDev;
-    }
+    private static double MaxRadialDeviation(List<Vector> points, double cx, double cy, double radius) =>
+        ArcFit.MaxRadialDeviation(points, cx, cy, radius);
 
     /// <summary>
     /// Measures the maximum distance from sampled points along the fitted arc

OpenNest.Core/Geometry/Shape.cs

@@ -532,9 +532,29 @@ namespace OpenNest.Geometry
             Line line, Line offsetLine,
             double distance, OffsetSide side, Shape offsetShape)
         {
-            Vector intersection;
+            // Determine if this is a convex corner using the cross product of
+            // the original line directions. Convex corners need an arc; concave
+            // corners use the line intersection (miter join).
+            var d1 = lastLine.EndPoint - lastLine.StartPoint;
+            var d2 = line.EndPoint - line.StartPoint;
+            var cross = d1.X * d2.Y - d1.Y * d2.X;
 
-            if (Intersect.IntersectsUnbounded(offsetLine, lastOffsetLine, out intersection))
+            var isConvex = (side == OffsetSide.Left && cross < -OpenNest.Math.Tolerance.Epsilon) ||
+                           (side == OffsetSide.Right && cross > OpenNest.Math.Tolerance.Epsilon);
+
+            if (isConvex)
+            {
+                var arc = new Arc(
+                    line.StartPoint,
+                    distance,
+                    line.StartPoint.AngleTo(lastOffsetLine.EndPoint),
+                    line.StartPoint.AngleTo(offsetLine.StartPoint),
+                    side == OffsetSide.Left
+                    );
+
+                offsetShape.Entities.Add(arc);
+            }
+            else if (Intersect.IntersectsUnbounded(offsetLine, lastOffsetLine, out var intersection))
             {
                 offsetLine.StartPoint = intersection;
                 lastOffsetLine.EndPoint = intersection;

OpenNest.Core/Geometry/SpatialQuery.cs

@@ -523,177 +523,17 @@ namespace OpenNest.Geometry
 
         #endregion
 
-        public static double ClosestDistanceLeft(Box box, List<Box> boxes)
-        {
-            var closestDistance = double.MaxValue;
-
-            for (int i = 0; i < boxes.Count; i++)
-            {
-                var compareBox = boxes[i];
-
-                RelativePosition pos;
-
-                if (!box.IsHorizontalTo(compareBox, out pos))
-                    continue;
-
-                if (pos != RelativePosition.Right)
-                    continue;
-
-                var distance = box.Left - compareBox.Right;
-
-                if (distance < closestDistance)
-                    closestDistance = distance;
-            }
-
-            return closestDistance == double.MaxValue ? double.NaN : closestDistance;
-        }
-
-        public static double ClosestDistanceRight(Box box, List<Box> boxes)
-        {
-            var closestDistance = double.MaxValue;
-
-            for (int i = 0; i < boxes.Count; i++)
-            {
-                var compareBox = boxes[i];
-
-                RelativePosition pos;
-
-                if (!box.IsHorizontalTo(compareBox, out pos))
-                    continue;
-
-                if (pos != RelativePosition.Left)
-                    continue;
-
-                var distance = compareBox.Left - box.Right;
-
-                if (distance < closestDistance)
-                    closestDistance = distance;
-            }
-
-            return closestDistance == double.MaxValue ? double.NaN : closestDistance;
-        }
-
-        public static double ClosestDistanceUp(Box box, List<Box> boxes)
-        {
-            var closestDistance = double.MaxValue;
-
-            for (int i = 0; i < boxes.Count; i++)
-            {
-                var compareBox = boxes[i];
-
-                RelativePosition pos;
-
-                if (!box.IsVerticalTo(compareBox, out pos))
-                    continue;
-
-                if (pos != RelativePosition.Bottom)
-                    continue;
-
-                var distance = compareBox.Bottom - box.Top;
-
-                if (distance < closestDistance)
-                    closestDistance = distance;
-            }
-
-            return closestDistance == double.MaxValue ? double.NaN : closestDistance;
-        }
-
-        public static double ClosestDistanceDown(Box box, List<Box> boxes)
-        {
-            var closestDistance = double.MaxValue;
-
-            for (int i = 0; i < boxes.Count; i++)
-            {
-                var compareBox = boxes[i];
-
-                RelativePosition pos;
-
-                if (!box.IsVerticalTo(compareBox, out pos))
-                    continue;
-
-                if (pos != RelativePosition.Top)
-                    continue;
-
-                var distance = box.Bottom - compareBox.Top;
-
-                if (distance < closestDistance)
-                    closestDistance = distance;
-            }
-
-            return closestDistance == double.MaxValue ? double.NaN : closestDistance;
-        }
-
         public static Box GetLargestBoxVertically(Vector pt, Box bounds, IEnumerable<Box> boxes)
         {
             var verticalBoxes = boxes.Where(b => !(b.Left > pt.X || b.Right < pt.X)).ToList();
 
-            #region Find Top/Bottom Limits
-
-            var top = double.MaxValue;
-            var btm = double.MinValue;
-
-            foreach (var box in verticalBoxes)
-            {
-                var boxBtm = box.Bottom;
-                var boxTop = box.Top;
-
-                if (boxBtm > pt.Y && boxBtm < top)
-                    top = boxBtm;
-
-                else if (box.Top < pt.Y && boxTop > btm)
-                    btm = boxTop;
-            }
-
-            if (top == double.MaxValue)
-            {
-                if (bounds.Top > pt.Y)
-                    top = bounds.Top;
-                else return Box.Empty;
-            }
-
-            if (btm == double.MinValue)
-            {
-                if (bounds.Bottom < pt.Y)
-                    btm = bounds.Bottom;
-                else return Box.Empty;
-            }
-
-            #endregion
+            if (!FindVerticalLimits(pt, bounds, verticalBoxes, out var top, out var btm))
+                return Box.Empty;
 
             var horizontalBoxes = boxes.Where(b => !(b.Bottom >= top || b.Top <= btm)).ToList();
 
-            #region Find Left/Right Limits
-
-            var lft = double.MinValue;
-            var rgt = double.MaxValue;
-
-            foreach (var box in horizontalBoxes)
-            {
-                var boxLft = box.Left;
-                var boxRgt = box.Right;
-
-                if (boxLft > pt.X && boxLft < rgt)
-                    rgt = boxLft;
-
-                else if (boxRgt < pt.X && boxRgt > lft)
-                    lft = boxRgt;
-            }
-
-            if (rgt == double.MaxValue)
-            {
-                if (bounds.Right > pt.X)
-                    rgt = bounds.Right;
-                else return Box.Empty;
-            }
-
-            if (lft == double.MinValue)
-            {
-                if (bounds.Left < pt.X)
-                    lft = bounds.Left;
-                else return Box.Empty;
-            }
-
-            #endregion
+            if (!FindHorizontalLimits(pt, bounds, horizontalBoxes, out var lft, out var rgt))
+                return Box.Empty;
 
             return new Box(lft, btm, rgt - lft, top - btm);
         }
@@ -702,75 +542,77 @@ namespace OpenNest.Geometry
         {
             var horizontalBoxes = boxes.Where(b => !(b.Bottom > pt.Y || b.Top < pt.Y)).ToList();
 
-            #region Find Left/Right Limits
-
-            var lft = double.MinValue;
-            var rgt = double.MaxValue;
-
-            foreach (var box in horizontalBoxes)
-            {
-                var boxLft = box.Left;
-                var boxRgt = box.Right;
-
-                if (boxLft > pt.X && boxLft < rgt)
-                    rgt = boxLft;
-
-                else if (boxRgt < pt.X && boxRgt > lft)
-                    lft = boxRgt;
-            }
-
-            if (rgt == double.MaxValue)
-            {
-                if (bounds.Right > pt.X)
-                    rgt = bounds.Right;
-                else return Box.Empty;
-            }
-
-            if (lft == double.MinValue)
-            {
-                if (bounds.Left < pt.X)
-                    lft = bounds.Left;
-                else return Box.Empty;
-            }
-
-            #endregion
+            if (!FindHorizontalLimits(pt, bounds, horizontalBoxes, out var lft, out var rgt))
+                return Box.Empty;
 
             var verticalBoxes = boxes.Where(b => !(b.Left >= rgt || b.Right <= lft)).ToList();
 
-            #region Find Top/Bottom Limits
+            if (!FindVerticalLimits(pt, bounds, verticalBoxes, out var top, out var btm))
+                return Box.Empty;
 
-            var top = double.MaxValue;
-            var btm = double.MinValue;
+            return new Box(lft, btm, rgt - lft, top - btm);
+        }
 
-            foreach (var box in verticalBoxes)
+        private static bool FindVerticalLimits(Vector pt, Box bounds, List<Box> boxes, out double top, out double btm)
+        {
+            top = double.MaxValue;
+            btm = double.MinValue;
+
+            foreach (var box in boxes)
             {
                 var boxBtm = box.Bottom;
                 var boxTop = box.Top;
 
                 if (boxBtm > pt.Y && boxBtm < top)
                     top = boxBtm;
-
                 else if (box.Top < pt.Y && boxTop > btm)
                     btm = boxTop;
             }
 
             if (top == double.MaxValue)
             {
-                if (bounds.Top > pt.Y)
-                    top = bounds.Top;
-                else return Box.Empty;
+                if (bounds.Top > pt.Y) top = bounds.Top;
+                else return false;
             }
 
             if (btm == double.MinValue)
             {
-                if (bounds.Bottom < pt.Y)
-                    btm = bounds.Bottom;
-                else return Box.Empty;
+                if (bounds.Bottom < pt.Y) btm = bounds.Bottom;
+                else return false;
             }
 
-            #endregion
+            return true;
+        }
 
-            return new Box(lft, btm, rgt - lft, top - btm);
+        private static bool FindHorizontalLimits(Vector pt, Box bounds, List<Box> boxes, out double lft, out double rgt)
+        {
+            lft = double.MinValue;
+            rgt = double.MaxValue;
+
+            foreach (var box in boxes)
+            {
+                var boxLft = box.Left;
+                var boxRgt = box.Right;
+
+                if (boxLft > pt.X && boxLft < rgt)
+                    rgt = boxLft;
+                else if (boxRgt < pt.X && boxRgt > lft)
+                    lft = boxRgt;
+            }
+
+            if (rgt == double.MaxValue)
+            {
+                if (bounds.Right > pt.X) rgt = bounds.Right;
+                else return false;
+            }
+
+            if (lft == double.MinValue)
+            {
+                if (bounds.Left < pt.X) lft = bounds.Left;
+                else return false;
+            }
+
+            return true;
         }
     }
 }

OpenNest.Core/Geometry/SplineConverter.cs

@@ -131,61 +131,11 @@ namespace OpenNest.Geometry
         }
 
         private static (Vector center, double radius, double deviation) FitWithStartTangent(
-            List<Vector> points, Vector tangent)
-        {
-            if (points.Count < 3)
-                return (Vector.Invalid, 0, double.MaxValue);
+            List<Vector> points, Vector tangent) =>
+            ArcFit.FitWithStartTangent(points, tangent);
 
-            var p1 = points[0];
-            var pn = points[^1];
-
-            var mx = (p1.X + pn.X) / 2;
-            var my = (p1.Y + pn.Y) / 2;
-            var dx = pn.X - p1.X;
-            var dy = pn.Y - p1.Y;
-            var chordLen = System.Math.Sqrt(dx * dx + dy * dy);
-            if (chordLen < 1e-10)
-                return (Vector.Invalid, 0, double.MaxValue);
-
-            var bx = -dy / chordLen;
-            var by = dx / chordLen;
-
-            var tLen = System.Math.Sqrt(tangent.X * tangent.X + tangent.Y * tangent.Y);
-            if (tLen < 1e-10)
-                return (Vector.Invalid, 0, double.MaxValue);
-
-            var nx = -tangent.Y / tLen;
-            var ny = tangent.X / tLen;
-
-            var det = nx * by - ny * bx;
-            if (System.Math.Abs(det) < 1e-10)
-                return (Vector.Invalid, 0, double.MaxValue);
-
-            var s = ((mx - p1.X) * by - (my - p1.Y) * bx) / det;
-
-            var cx = p1.X + s * nx;
-            var cy = p1.Y + s * ny;
-            var radius = System.Math.Sqrt((cx - p1.X) * (cx - p1.X) + (cy - p1.Y) * (cy - p1.Y));
-
-            if (radius < 1e-10)
-                return (Vector.Invalid, 0, double.MaxValue);
-
-            return (new Vector(cx, cy), radius, MaxRadialDeviation(points, cx, cy, radius));
-        }
-
-        private static double MaxRadialDeviation(List<Vector> points, double cx, double cy, double radius)
-        {
-            var maxDev = 0.0;
-            for (var i = 1; i < points.Count - 1; i++)
-            {
-                var px = points[i].X - cx;
-                var py = points[i].Y - cy;
-                var dist = System.Math.Sqrt(px * px + py * py);
-                var dev = System.Math.Abs(dist - radius);
-                if (dev > maxDev) maxDev = dev;
-            }
-            return maxDev;
-        }
+        private static double MaxRadialDeviation(List<Vector> points, double cx, double cy, double radius) =>
+            ArcFit.MaxRadialDeviation(points, cx, cy, radius);
 
         private static double SumSignedAngles(Vector center, List<Vector> points)
         {

OpenNest.Core/Part.cs

@@ -171,56 +171,18 @@ namespace OpenNest
             if (perimeter1 == null || perimeter2 == null)
                 return false;
 
-            perimeter1.Offset(Location);
-            perimeter2.Offset(part.Location);
+            var polygon1 = perimeter1.ToPolygon();
+            var polygon2 = perimeter2.ToPolygon();
 
-            if (!perimeter1.Intersects(perimeter2, out var rawPts))
+            if (polygon1 == null || polygon2 == null)
                 return false;
 
-            // Exclude intersection points that coincide with vertices of BOTH
-            // perimeters — these are touch points (shared corners/endpoints),
-            // not actual crossings where one shape enters the other's interior.
-            var verts1 = CollectVertices(perimeter1);
-            var verts2 = CollectVertices(perimeter2);
+            polygon1.Offset(Location);
+            polygon2.Offset(part.Location);
 
-            foreach (var pt in rawPts)
-            {
-                if (IsNearAnyVertex(pt, verts1) && IsNearAnyVertex(pt, verts2))
-                    continue;
-                pts.Add(pt);
-            }
-
-            return pts.Count > 0;
-        }
-
-        private static List<Vector> CollectVertices(Geometry.Shape shape)
-        {
-            var verts = new List<Vector>();
-            foreach (var entity in shape.Entities)
-            {
-                switch (entity)
-                {
-                    case Geometry.Line line:
-                        verts.Add(line.StartPoint);
-                        verts.Add(line.EndPoint);
-                        break;
-                    case Geometry.Arc arc:
-                        verts.Add(arc.StartPoint());
-                        verts.Add(arc.EndPoint());
-                        break;
-                }
-            }
-            return verts;
-        }
-
-        private static bool IsNearAnyVertex(Vector pt, List<Vector> vertices)
-        {
-            foreach (var v in vertices)
-            {
-                if (pt.X.IsEqualTo(v.X) && pt.Y.IsEqualTo(v.Y))
-                    return true;
-            }
-            return false;
+            var result = Geometry.Collision.Check(polygon1, polygon2);
+            pts = result.IntersectionPoints.ToList();
+            return result.Overlaps;
         }
 
         public double Left

OpenNest.Core/PartGeometry.cs

@@ -45,7 +45,7 @@ namespace OpenNest
             var profile = new ShapeProfile(
                 entities.Where(e => e.Layer != SpecialLayers.Rapid).ToList());
             var lines = new List<Line>();
-            var totalSpacing = spacing + chordTolerance;
+            var totalSpacing = spacing;
 
             AddOffsetLines(lines, profile.Perimeter.OffsetOutward(totalSpacing),
                 chordTolerance, part.Location);
@@ -63,7 +63,7 @@ namespace OpenNest
             var profile = new ShapeProfile(
                 entities.Where(e => e.Layer != SpecialLayers.Rapid).ToList());
             var lines = new List<Line>();
-            var totalSpacing = spacing + chordTolerance;
+            var totalSpacing = spacing;
 
             AddOffsetDirectionalLines(lines, profile.Perimeter.OffsetOutward(totalSpacing),
                 chordTolerance, part.Location, facingDirection);
@@ -97,7 +97,7 @@ namespace OpenNest
             var profile = new ShapeProfile(
                 entities.Where(e => e.Layer != SpecialLayers.Rapid).ToList());
             var lines = new List<Line>();
-            var totalSpacing = spacing + chordTolerance;
+            var totalSpacing = spacing;
 
             AddOffsetDirectionalLines(lines, profile.Perimeter.OffsetOutward(totalSpacing),
                 chordTolerance, part.Location, facingDirection);

OpenNest.Engine/CirclePacking/FillEndOdd.cs

@@ -27,7 +27,11 @@ namespace OpenNest.CirclePacking
             throw new NotImplementedException();
         }
 
-        private Bin FillHorizontal(Item item)
+        private Bin FillHorizontal(Item item) => FillAxis(item, horizontal: true);
+
+        private Bin FillVertical(Item item) => FillAxis(item, horizontal: false);
+
+        private Bin FillAxis(Item item, bool horizontal)
         {
             var bin = Bin.Clone() as Bin;
 
@@ -35,65 +39,36 @@ namespace OpenNest.CirclePacking
                 bin.Right - item.BoundingBox.Right + Tolerance.Epsilon,
                 bin.Top - item.BoundingBox.Top + Tolerance.Epsilon);
 
-            var count = System.Math.Floor((bin.Width + Tolerance.Epsilon) / item.Diameter);
+            var primarySize = horizontal ? bin.Width : bin.Length;
+            var count = System.Math.Floor((primarySize + Tolerance.Epsilon) / item.Diameter);
 
             if (count == 0)
                 return bin;
 
-            var xoffset = (bin.Width - item.Diameter) / (count - 1);
-            var yoffset = Trigonometry.Height(xoffset * 0.5, item.Diameter);
+            var primaryOffset = (primarySize - item.Diameter) / (count - 1);
+            var secondaryOffset = horizontal
+                ? Trigonometry.Height(primaryOffset * 0.5, item.Diameter)
+                : Trigonometry.Base(primaryOffset * 0.5, item.Diameter);
 
-            int row = 0;
+            var outerStart = horizontal ? bin.Y : bin.X;
+            var outerMax = horizontal ? max.Y : max.X;
+            var innerStart = horizontal ? bin.X : bin.Y;
+            var innerMax = horizontal ? max.X : max.Y;
 
-            for (var y = bin.Y; y <= max.Y; y += yoffset)
+            var stripe = 0;
+
+            for (var outer = outerStart; outer <= outerMax; outer += secondaryOffset)
             {
-                var x = row.IsOdd() ? bin.X + xoffset * 0.5 : bin.X;
+                var inner = stripe.IsOdd() ? innerStart + primaryOffset * 0.5 : innerStart;
 
-                for (; x <= max.X; x += xoffset)
+                for (; inner <= innerMax; inner += primaryOffset)
                 {
                     var addedItem = item.Clone() as Item;
-                    addedItem.Center = new Vector(x, y);
-
+                    addedItem.Center = horizontal ? new Vector(inner, outer) : new Vector(outer, inner);
                     bin.Items.Add(addedItem);
                 }
 
-                row++;
-            }
-
-            return bin;
-        }
-
-        private Bin FillVertical(Item item)
-        {
-            var bin = Bin.Clone() as Bin;
-
-            var max = new Vector(
-                Bin.Right - item.BoundingBox.Right + Tolerance.Epsilon,
-                Bin.Top - item.BoundingBox.Top + Tolerance.Epsilon);
-
-            var count = System.Math.Floor((bin.Length + Tolerance.Epsilon) / item.Diameter);
-
-            if (count == 0)
-                return bin;
-
-            var yoffset = (bin.Length - item.Diameter) / (count - 1);
-            var xoffset = Trigonometry.Base(yoffset * 0.5, item.Diameter);
-
-            int column = 0;
-
-            for (var x = bin.X; x <= max.X; x += xoffset)
-            {
-                var y = column.IsOdd() ? bin.Y + yoffset * 0.5 : bin.Y;
-
-                for (; y <= max.Y; y += yoffset)
-                {
-                    var addedItem = item.Clone() as Item;
-                    addedItem.Center = new Vector(x, y);
-
-                    bin.Items.Add(addedItem);
-                }
-
-                column++;
+                stripe++;
             }
 
             return bin;

OpenNest.Engine/DefaultNestEngine.cs

@@ -94,7 +94,7 @@ namespace OpenNest
 
             // Multi-part group: linear pattern fill only.
             PhaseResults.Clear();
-            var engine = new FillLinear(workArea, Plate.PartSpacing);
+            var engine = new FillLinear(workArea, Plate.PartSpacing) { Label = "GroupPattern" };
             var angles = RotationAnalysis.FindHullEdgeAngles(groupParts);
             var best = FillHelpers.FillPattern(engine, groupParts, angles, workArea, Comparer);
             PhaseResults.Add(new PhaseResult(NestPhase.Linear, best?.Count ?? 0, 0));

OpenNest.Engine/Fill/FillExtents.cs

@@ -1,9 +1,9 @@
+using OpenNest.Engine.Strategies;
 using OpenNest.Geometry;
 using OpenNest.Math;
 using System;
 using System.Collections.Generic;
 using System.Diagnostics;
-using System.Linq;
 using System.Threading;
 
 namespace OpenNest.Engine.Fill
@@ -33,7 +33,7 @@ namespace OpenNest.Engine.Fill
             if (pair == null)
                 return new List<Part>();
 
-            var column = BuildColumn(pair.Value.part1, pair.Value.part2, pair.Value.pairBbox);
+            var column = BuildColumn(pair.Value);
             if (column.Count == 0)
                 return new List<Part>();
 
@@ -81,7 +81,7 @@ namespace OpenNest.Engine.Fill
 
         // --- Step 1: Pair Construction ---
 
-        private (Part part1, Part part2, Box pairBbox)? BuildPair(Drawing drawing, double rotationAngle)
+        private PartPair? BuildPair(Drawing drawing, double rotationAngle)
         {
             var part1 = Part.CreateAtOrigin(drawing, rotationAngle);
             var part2 = Part.CreateAtOrigin(drawing, rotationAngle + System.Math.PI);
@@ -111,46 +111,40 @@ namespace OpenNest.Engine.Fill
                 part2.UpdateBounds();
             }
 
-            // Re-anchor pair to work area origin.
-            var pairBbox = ((IEnumerable<IBoundable>)new IBoundable[] { part1, part2 }).GetBoundingBox();
-            var anchor = new Vector(workArea.X - pairBbox.Left, workArea.Y - pairBbox.Bottom);
-            part1.Offset(anchor);
-            part2.Offset(anchor);
-            part1.UpdateBounds();
-            part2.UpdateBounds();
-
-            pairBbox = ((IEnumerable<IBoundable>)new IBoundable[] { part1, part2 }).GetBoundingBox();
-
-            // Verify pair fits in work area.
-            if (pairBbox.Width > workArea.Width + Tolerance.Epsilon ||
-                pairBbox.Length > workArea.Length + Tolerance.Epsilon)
+            var pair = AnchorToWorkArea(part1, part2);
+            if (pair == null)
                 return null;
 
-            return (part1, part2, pairBbox);
+            // Verify pair fits in work area.
+            if (pair.Value.Bbox.Width > workArea.Width + Tolerance.Epsilon ||
+                pair.Value.Bbox.Length > workArea.Length + Tolerance.Epsilon)
+                return null;
+
+            return pair;
         }
 
         // --- Step 2: Build Column (tile vertically) ---
 
-        private List<Part> BuildColumn(Part part1, Part part2, Box pairBbox)
+        private List<Part> BuildColumn(PartPair pair)
         {
-            var column = new List<Part> { (Part)part1.Clone(), (Part)part2.Clone() };
+            var column = new List<Part> { (Part)pair.Part1.Clone(), (Part)pair.Part2.Clone() };
 
             // Find geometry-aware copy distance for the pair vertically.
-            var boundary1 = new PartBoundary(part1, halfSpacing);
-            var boundary2 = new PartBoundary(part2, halfSpacing);
+            var boundary1 = new PartBoundary(pair.Part1, halfSpacing);
+            var boundary2 = new PartBoundary(pair.Part2, halfSpacing);
 
             // Compute vertical copy distance using bounding boxes as starting point,
             // then slide down to find true geometry distance.
-            var pairHeight = pairBbox.Length;
+            var pairHeight = pair.Bbox.Length;
             var testOffset = new Vector(0, pairHeight);
 
             // Create test parts for slide distance measurement.
-            var testPart1 = part1.CloneAtOffset(testOffset);
-            var testPart2 = part2.CloneAtOffset(testOffset);
+            var testPart1 = pair.Part1.CloneAtOffset(testOffset);
+            var testPart2 = pair.Part2.CloneAtOffset(testOffset);
 
             // Find minimum distance from test pair sliding down toward original pair.
             var copyDistance = FindVerticalCopyDistance(
-                part1, part2, testPart1, testPart2,
+                pair.Part1, pair.Part2, testPart1, testPart2,
                 boundary1, boundary2, pairHeight);
 
             if (copyDistance <= 0)
@@ -159,13 +153,13 @@ namespace OpenNest.Engine.Fill
             var count = 1;
             while (true)
             {
-                var nextBottom = pairBbox.Bottom + copyDistance * count;
+                var nextBottom = pair.Bbox.Bottom + copyDistance * count;
                 if (nextBottom + pairHeight > workArea.Top + Tolerance.Epsilon)
                     break;
 
                 var offset = new Vector(0, copyDistance * count);
-                column.Add(part1.CloneAtOffset(offset));
-                column.Add(part2.CloneAtOffset(offset));
+                column.Add(pair.Part1.CloneAtOffset(offset));
+                column.Add(pair.Part2.CloneAtOffset(offset));
                 count++;
             }
 
@@ -179,23 +173,20 @@ namespace OpenNest.Engine.Fill
             double pairHeight)
         {
             // Check all 4 combinations: test parts sliding down toward original parts.
+            var slidePairs = new[]
+            {
+                (moving: boundary1, movingLoc: testPart1.Location, stationary: boundary1, stationaryLoc: origPart1.Location),
+                (moving: boundary1, movingLoc: testPart1.Location, stationary: boundary2, stationaryLoc: origPart2.Location),
+                (moving: boundary2, movingLoc: testPart2.Location, stationary: boundary1, stationaryLoc: origPart1.Location),
+                (moving: boundary2, movingLoc: testPart2.Location, stationary: boundary2, stationaryLoc: origPart2.Location),
+            };
+
             var minSlide = double.MaxValue;
-
-            // Test1 -> Orig1
-            var d = SlideDistance(boundary1, testPart1.Location, boundary1, origPart1.Location, PushDirection.Down);
-            if (d < minSlide) minSlide = d;
-
-            // Test1 -> Orig2
-            d = SlideDistance(boundary1, testPart1.Location, boundary2, origPart2.Location, PushDirection.Down);
-            if (d < minSlide) minSlide = d;
-
-            // Test2 -> Orig1
-            d = SlideDistance(boundary2, testPart2.Location, boundary1, origPart1.Location, PushDirection.Down);
-            if (d < minSlide) minSlide = d;
-
-            // Test2 -> Orig2
-            d = SlideDistance(boundary2, testPart2.Location, boundary2, origPart2.Location, PushDirection.Down);
-            if (d < minSlide) minSlide = d;
+            foreach (var (moving, movingLoc, stationary, stationaryLoc) in slidePairs)
+            {
+                var d = SlideDistance(moving, movingLoc, stationary, stationaryLoc, PushDirection.Down);
+                if (d < minSlide) minSlide = d;
+            }
 
             if (minSlide >= double.MaxValue || minSlide < 0)
                 return pairHeight + partSpacing;
@@ -225,12 +216,9 @@ namespace OpenNest.Engine.Fill
 
         // --- Step 3: Iterative Adjustment ---
 
-        private List<Part> AdjustColumn(
-            (Part part1, Part part2, Box pairBbox) pair,
-            List<Part> column,
-            CancellationToken token)
+        private List<Part> AdjustColumn(PartPair pair, List<Part> column, CancellationToken token)
         {
-            var originalPairWidth = pair.pairBbox.Width;
+            var originalPairWidth = pair.Bbox.Width;
 
             for (var iteration = 0; iteration < MaxIterations; iteration++)
             {
@@ -261,7 +249,7 @@ namespace OpenNest.Engine.Fill
                 if (adjusted == null)
                     break;
 
-                var newColumn = BuildColumn(adjusted.Value.part1, adjusted.Value.part2, adjusted.Value.pairBbox);
+                var newColumn = BuildColumn(adjusted.Value);
                 if (newColumn.Count == 0)
                     break;
 
@@ -272,9 +260,7 @@ namespace OpenNest.Engine.Fill
             return column;
         }
 
-        private (Part part1, Part part2, Box pairBbox)? TryAdjustPair(
-            (Part part1, Part part2, Box pairBbox) pair,
-            double adjustment, double originalPairWidth)
+        private PartPair? TryAdjustPair(PartPair pair, double adjustment, double originalPairWidth)
         {
             // Try shifting part2 up first.
             var result = TryShiftDirection(pair, adjustment, originalPairWidth);
@@ -286,13 +272,11 @@ namespace OpenNest.Engine.Fill
             return TryShiftDirection(pair, -adjustment, originalPairWidth);
         }
 
-        private (Part part1, Part part2, Box pairBbox)? TryShiftDirection(
-            (Part part1, Part part2, Box pairBbox) pair,
-            double verticalShift, double originalPairWidth)
+        private PartPair? TryShiftDirection(PartPair pair, double verticalShift, double originalPairWidth)
         {
             // Clone parts so we don't mutate the originals.
-            var p1 = (Part)pair.part1.Clone();
-            var p2 = (Part)pair.part2.Clone();
+            var p1 = (Part)pair.Part1.Clone();
+            var p2 = (Part)pair.Part2.Clone();
 
             // Separate: shift part2 right so bounding boxes don't touch.
             p2.Offset(partSpacing, 0);
@@ -308,20 +292,12 @@ namespace OpenNest.Engine.Fill
             Compactor.Push(moving, obstacles, workArea, partSpacing, PushDirection.Left);
 
             // Check if the pair got wider.
-            var newBbox = ((IEnumerable<IBoundable>)new IBoundable[] { p1, p2 }).GetBoundingBox();
+            var newBbox = PairBbox(p1, p2);
 
             if (newBbox.Width > originalPairWidth + Tolerance.Epsilon)
                 return null;
 
-            // Re-anchor to work area origin.
-            var anchor = new Vector(workArea.X - newBbox.Left, workArea.Y - newBbox.Bottom);
-            p1.Offset(anchor);
-            p2.Offset(anchor);
-            p1.UpdateBounds();
-            p2.UpdateBounds();
-
-            newBbox = ((IEnumerable<IBoundable>)new IBoundable[] { p1, p2 }).GetBoundingBox();
-            return (p1, p2, newBbox);
+            return AnchorToWorkArea(p1, p2);
         }
 
         // --- Step 4: Horizontal Repetition ---
@@ -331,110 +307,35 @@ namespace OpenNest.Engine.Fill
             if (column.Count == 0)
                 return column;
 
-            var columnBbox = ((IEnumerable<IBoundable>)column).GetBoundingBox();
-            var columnWidth = columnBbox.Width;
+            var pattern = new Pattern();
+            pattern.Parts.AddRange(column);
+            pattern.UpdateBounds();
 
-            // Create a test column shifted right by columnWidth + spacing.
-            var testOffset = columnWidth + partSpacing;
-            var testColumn = new List<Part>(column.Count);
-            foreach (var part in column)
-                testColumn.Add(part.CloneAtOffset(new Vector(testOffset, 0)));
-
-            // Compact the test column left against the original column.
-            var distanceMoved = Compactor.Push(testColumn, column, workArea, partSpacing, PushDirection.Left);
-
-            // Derive the true copy distance from where the test column ended up.
-            var testBbox = ((IEnumerable<IBoundable>)testColumn).GetBoundingBox();
-            var copyDistance = testBbox.Left - columnBbox.Left;
-
-            if (copyDistance <= Tolerance.Epsilon)
-                copyDistance = columnWidth + partSpacing;
-
-            // Safety: if the compacted test column overlaps the original column,
-            // fall back to bbox-based spacing.
-            var probe = new List<Part>(column);
-            probe.AddRange(testColumn.Where(IsWithinWorkArea));
-            if (HasOverlappingParts(probe))
-            {
-                Debug.WriteLine($"[FillExtents] Compacted column overlaps, falling back to bbox spacing");
-                copyDistance = columnWidth + partSpacing;
-
-                // Rebuild test column at safe distance.
-                testColumn.Clear();
-                foreach (var part in column)
-                    testColumn.Add(part.CloneAtOffset(new Vector(copyDistance, 0)));
-            }
-
-            Debug.WriteLine($"[FillExtents] Column copy distance: {copyDistance:F2} (bbox width: {columnWidth:F2}, spacing: {partSpacing:F2})");
-
-            // Build all columns.
-            var result = new List<Part>(column);
-
-            // Add the test column we already computed as column 2.
-            foreach (var part in testColumn)
-            {
-                if (IsWithinWorkArea(part))
-                    result.Add(part);
-            }
-
-            // Tile additional columns at the copy distance.
-            var colIndex = 2;
-            while (!token.IsCancellationRequested)
-            {
-                var offset = new Vector(copyDistance * colIndex, 0);
-                var anyFit = false;
-
-                foreach (var part in column)
-                {
-                    var clone = part.CloneAtOffset(offset);
-                    if (IsWithinWorkArea(clone))
-                    {
-                        result.Add(clone);
-                        anyFit = true;
-                    }
-                }
-
-                if (!anyFit)
-                    break;
-
-                colIndex++;
-            }
-
-            return result;
+            var linear = new FillLinear(workArea, partSpacing);
+            return linear.Fill(pattern, NestDirection.Horizontal);
         }
 
-        private bool IsWithinWorkArea(Part part)
+        // --- Helpers ---
+
+        private PartPair? AnchorToWorkArea(Part part1, Part part2)
         {
-            return part.BoundingBox.Right <= workArea.Right + Tolerance.Epsilon &&
-                   part.BoundingBox.Top <= workArea.Top + Tolerance.Epsilon &&
-                   part.BoundingBox.Left >= workArea.Left - Tolerance.Epsilon &&
-                   part.BoundingBox.Bottom >= workArea.Bottom - Tolerance.Epsilon;
+            var bbox = PairBbox(part1, part2);
+            var anchor = new Vector(workArea.X - bbox.Left, workArea.Y - bbox.Bottom);
+            part1.Offset(anchor);
+            part2.Offset(anchor);
+            part1.UpdateBounds();
+            part2.UpdateBounds();
+
+            bbox = PairBbox(part1, part2);
+            return new PartPair(part1, part2, bbox);
         }
 
-        private static bool HasOverlappingParts(List<Part> parts)
-        {
-            for (var i = 0; i < parts.Count; i++)
-            {
-                var b1 = parts[i].BoundingBox;
+        private static Box PairBbox(Part part1, Part part2) =>
+            ((IEnumerable<IBoundable>)new IBoundable[] { part1, part2 }).GetBoundingBox();
 
-                for (var j = i + 1; j < parts.Count; j++)
-                {
-                    var b2 = parts[j].BoundingBox;
+        private static bool HasOverlappingParts(List<Part> parts) =>
+            FillHelpers.HasOverlappingParts(parts);
 
-                    var overlapX = System.Math.Min(b1.Right, b2.Right)
-                                 - System.Math.Max(b1.Left, b2.Left);
-                    var overlapY = System.Math.Min(b1.Top, b2.Top)
-                                 - System.Math.Max(b1.Bottom, b2.Bottom);
-
-                    if (overlapX <= Tolerance.Epsilon || overlapY <= Tolerance.Epsilon)
-                        continue;
-
-                    if (parts[i].Intersects(parts[j], out _))
-                        return true;
-                }
-            }
-
-            return false;
-        }
+        private readonly record struct PartPair(Part Part1, Part Part2, Box Bbox);
     }
 }

OpenNest.Engine/Fill/FillLinear.cs

@@ -1,6 +1,7 @@
 using OpenNest.Geometry;
 using OpenNest.Math;
 using System.Collections.Generic;
+using System.Diagnostics;
 using System.Threading.Tasks;
 
 namespace OpenNest.Engine.Fill
@@ -19,6 +20,11 @@ namespace OpenNest.Engine.Fill
 
         public double HalfSpacing => PartSpacing / 2;
 
+        /// <summary>
+        /// Diagnostic label set by callers to identify the engine/context in overlap logs.
+        /// </summary>
+        public string Label { get; set; }
+
         private static Vector MakeOffset(NestDirection direction, double distance)
         {
             return direction == NestDirection.Horizontal
@@ -323,7 +329,7 @@ namespace OpenNest.Engine.Fill
             return result;
         }
 
-        private static bool HasOverlappingParts(List<Part> parts)
+        private static bool HasOverlappingParts(List<Part> parts, out int overlapA, out int overlapB)
         {
             for (var i = 0; i < parts.Count; i++)
             {
@@ -338,11 +344,20 @@ namespace OpenNest.Engine.Fill
                     var overlapY = System.Math.Min(b1.Top, b2.Top)
                                  - System.Math.Max(b1.Bottom, b2.Bottom);
 
-                    if (overlapX > Tolerance.Epsilon && overlapY > Tolerance.Epsilon)
+                    if (overlapX <= Tolerance.Epsilon || overlapY <= Tolerance.Epsilon)
+                        continue;
+
+                    if (parts[i].Intersects(parts[j], out _))
+                    {
+                        overlapA = i;
+                        overlapB = j;
                         return true;
+                    }
                 }
             }
 
+            overlapA = -1;
+            overlapB = -1;
             return false;
         }
 
@@ -384,10 +399,9 @@ namespace OpenNest.Engine.Fill
             var row = new List<Part>(pattern.Parts);
             row.AddRange(TilePattern(pattern, direction, boundaries));
 
-            // Safety: if geometry-aware spacing produced overlapping parts,
-            // fall back to bbox-based spacing for this axis.
-            if (pattern.Parts.Count > 1 && HasOverlappingParts(row))
+            if (pattern.Parts.Count > 1 && HasOverlappingParts(row, out var a1, out var b1))
             {
+                LogOverlap("Step1-Primary", direction, pattern, row, a1, b1);
                 row = new List<Part>(pattern.Parts);
                 row.AddRange(TilePatternBbox(pattern, direction));
             }
@@ -397,8 +411,9 @@ namespace OpenNest.Engine.Fill
             {
                 row.AddRange(TilePattern(pattern, perpAxis, boundaries));
 
-                if (pattern.Parts.Count > 1 && HasOverlappingParts(row))
+                if (pattern.Parts.Count > 1 && HasOverlappingParts(row, out var a2, out var b2))
                 {
+                    LogOverlap("Step1-PerpOnly", perpAxis, pattern, row, a2, b2);
                     row = new List<Part>(pattern.Parts);
                     row.AddRange(TilePatternBbox(pattern, perpAxis));
                 }
@@ -415,9 +430,45 @@ namespace OpenNest.Engine.Fill
             var gridResult = new List<Part>(rowPattern.Parts);
             gridResult.AddRange(TilePattern(rowPattern, perpAxis, rowBoundaries));
 
+            if (HasOverlappingParts(gridResult, out var a3, out var b3))
+            {
+                LogOverlap("Step2-Perp", perpAxis, rowPattern, gridResult, a3, b3);
+                gridResult = new List<Part>(rowPattern.Parts);
+                gridResult.AddRange(TilePatternBbox(rowPattern, perpAxis));
+            }
+
             return gridResult;
         }
 
+        private void LogOverlap(string step, NestDirection tilingDir,
+            Pattern pattern, List<Part> parts, int idxA, int idxB)
+        {
+            var pa = parts[idxA];
+            var pb = parts[idxB];
+            var ba = pa.BoundingBox;
+            var bb = pb.BoundingBox;
+
+            Debug.WriteLine($"[FillLinear] OVERLAP FALLBACK ({Label ?? "unknown"})");
+            Debug.WriteLine($"  Step: {step}, TilingDir: {tilingDir}");
+            Debug.WriteLine($"  WorkArea: ({WorkArea.X:F4},{WorkArea.Y:F4}) {WorkArea.Width:F4}x{WorkArea.Length:F4}, Spacing: {PartSpacing}");
+            Debug.WriteLine($"  Pattern: {pattern.Parts.Count} parts, bbox {pattern.BoundingBox.Width:F4}x{pattern.BoundingBox.Length:F4}");
+            Debug.WriteLine($"  Total parts after tiling: {parts.Count}");
+            Debug.WriteLine($"  Overlapping pair [{idxA}] vs [{idxB}]:");
+            Debug.WriteLine($"    [{idxA}]: drawing={pa.BaseDrawing?.Name ?? "?"} rot={Angle.ToDegrees(pa.Rotation):F2}° " +
+                $"loc=({pa.Location.X:F4},{pa.Location.Y:F4}) bbox=({ba.Left:F4},{ba.Bottom:F4})-({ba.Right:F4},{ba.Top:F4})");
+            Debug.WriteLine($"    [{idxB}]: drawing={pb.BaseDrawing?.Name ?? "?"} rot={Angle.ToDegrees(pb.Rotation):F2}° " +
+                $"loc=({pb.Location.X:F4},{pb.Location.Y:F4}) bbox=({bb.Left:F4},{bb.Bottom:F4})-({bb.Right:F4},{bb.Top:F4})");
+
+            // Log all pattern seed parts for reproduction
+            Debug.WriteLine($"  Pattern seed parts:");
+            for (var i = 0; i < pattern.Parts.Count; i++)
+            {
+                var p = pattern.Parts[i];
+                Debug.WriteLine($"    [{i}]: drawing={p.BaseDrawing?.Name ?? "?"} rot={Angle.ToDegrees(p.Rotation):F2}° " +
+                    $"loc=({p.Location.X:F4},{p.Location.Y:F4}) bbox={p.BoundingBox.Width:F4}x{p.BoundingBox.Length:F4}");
+            }
+        }
+
         /// <summary>
         /// Fills a single row of identical parts along one axis using geometry-aware spacing.
         /// </summary>

OpenNest.Engine/Fill/IterativeShrinkFiller.cs

@@ -167,134 +167,84 @@ namespace OpenNest.Engine.Fill
         /// Sorts pair columns by height (shortest first on the left) to create
         /// a staircase profile that maximizes usable remnant area.
         /// </summary>
-        internal static void SortColumnsByHeight(List<Part> parts, double spacing)
-        {
-            if (parts == null || parts.Count <= 1)
-                return;
-
-            // Sort parts by Left edge for grouping.
-            parts.Sort((a, b) => a.BoundingBox.Left.CompareTo(b.BoundingBox.Left));
-
-            // Group parts into columns by X overlap.
-            var columns = new List<List<Part>>();
-            var column = new List<Part> { parts[0] };
-            var columnRight = parts[0].BoundingBox.Right;
-
-            for (var i = 1; i < parts.Count; i++)
-            {
-                if (parts[i].BoundingBox.Left > columnRight + spacing / 2)
-                {
-                    columns.Add(column);
-                    column = new List<Part> { parts[i] };
-                    columnRight = parts[i].BoundingBox.Right;
-                }
-                else
-                {
-                    column.Add(parts[i]);
-                    if (parts[i].BoundingBox.Right > columnRight)
-                        columnRight = parts[i].BoundingBox.Right;
-                }
-            }
-            columns.Add(column);
-
-            if (columns.Count <= 1)
-                return;
-
-            // Measure inter-column gap from original layout.
-            var gap = MinLeft(columns[1]) - MaxRight(columns[0]);
-
-            // Sort columns by height ascending (shortest first).
-            columns.Sort((a, b) => MaxTop(a).CompareTo(MaxTop(b)));
-
-            // Reposition columns left-to-right.
-            var x = parts[0].BoundingBox.Left; // parts already sorted by Left
-
-            foreach (var col in columns)
-            {
-                var colLeft = MinLeft(col);
-                var dx = x - colLeft;
-
-                if (System.Math.Abs(dx) > OpenNest.Math.Tolerance.Epsilon)
-                {
-                    var offset = new Vector(dx, 0);
-                    foreach (var part in col)
-                        part.Offset(offset);
-                }
-
-                x = MaxRight(col) + gap;
-            }
-
-            // Rebuild the parts list in column order.
-            parts.Clear();
-            foreach (var col in columns)
-                parts.AddRange(col);
-        }
+        internal static void SortColumnsByHeight(List<Part> parts, double spacing) =>
+            SortStrips(parts, spacing,
+                primaryEdge: b => b.Left, extentEdge: b => b.Right,
+                sortMetric: MaxTop, stripMin: MinLeft, stripMax: MaxRight,
+                makeOffset: d => new Vector(d, 0));
 
         /// <summary>
         /// Sorts pair rows by width (narrowest first on the bottom) to create
         /// a staircase profile on the right side that maximizes usable remnant area.
         /// </summary>
-        internal static void SortRowsByWidth(List<Part> parts, double spacing)
+        internal static void SortRowsByWidth(List<Part> parts, double spacing) =>
+            SortStrips(parts, spacing,
+                primaryEdge: b => b.Bottom, extentEdge: b => b.Top,
+                sortMetric: MaxRight, stripMin: MinBottom, stripMax: MaxTop,
+                makeOffset: d => new Vector(0, d));
+
+        private static void SortStrips(
+            List<Part> parts, double spacing,
+            Func<Box, double> primaryEdge,
+            Func<Box, double> extentEdge,
+            Func<List<Part>, double> sortMetric,
+            Func<List<Part>, double> stripMin,
+            Func<List<Part>, double> stripMax,
+            Func<double, Vector> makeOffset)
         {
             if (parts == null || parts.Count <= 1)
                 return;
 
-            // Sort parts by Bottom edge for grouping.
-            parts.Sort((a, b) => a.BoundingBox.Bottom.CompareTo(b.BoundingBox.Bottom));
+            parts.Sort((a, b) => primaryEdge(a.BoundingBox).CompareTo(primaryEdge(b.BoundingBox)));
 
-            // Group parts into rows by Y overlap.
-            var rows = new List<List<Part>>();
-            var row = new List<Part> { parts[0] };
-            var rowTop = parts[0].BoundingBox.Top;
+            var strips = new List<List<Part>>();
+            var strip = new List<Part> { parts[0] };
+            var stripExtent = extentEdge(parts[0].BoundingBox);
 
             for (var i = 1; i < parts.Count; i++)
             {
-                if (parts[i].BoundingBox.Bottom > rowTop + spacing / 2)
+                if (primaryEdge(parts[i].BoundingBox) > stripExtent + spacing / 2)
                 {
-                    rows.Add(row);
-                    row = new List<Part> { parts[i] };
-                    rowTop = parts[i].BoundingBox.Top;
+                    strips.Add(strip);
+                    strip = new List<Part> { parts[i] };
+                    stripExtent = extentEdge(parts[i].BoundingBox);
                 }
                 else
                 {
-                    row.Add(parts[i]);
-                    if (parts[i].BoundingBox.Top > rowTop)
-                        rowTop = parts[i].BoundingBox.Top;
+                    strip.Add(parts[i]);
+                    var extent = extentEdge(parts[i].BoundingBox);
+                    if (extent > stripExtent)
+                        stripExtent = extent;
                 }
             }
-            rows.Add(row);
+            strips.Add(strip);
 
-            if (rows.Count <= 1)
+            if (strips.Count <= 1)
                 return;
 
-            // Measure inter-row gap from original layout.
-            var gap = MinBottom(rows[1]) - MaxTop(rows[0]);
+            var gap = stripMin(strips[1]) - stripMax(strips[0]);
 
-            // Sort rows by width ascending (narrowest first).
-            rows.Sort((a, b) => MaxRight(a).CompareTo(MaxRight(b)));
+            strips.Sort((a, b) => sortMetric(a).CompareTo(sortMetric(b)));
 
-            // Reposition rows bottom-to-top.
-            var y = parts[0].BoundingBox.Bottom; // parts already sorted by Bottom
+            var pos = primaryEdge(parts[0].BoundingBox);
 
-            foreach (var r in rows)
+            foreach (var s in strips)
             {
-                var rowBottom = MinBottom(r);
-                var dy = y - rowBottom;
+                var delta = pos - stripMin(s);
 
-                if (System.Math.Abs(dy) > OpenNest.Math.Tolerance.Epsilon)
+                if (System.Math.Abs(delta) > OpenNest.Math.Tolerance.Epsilon)
                 {
-                    var offset = new Vector(0, dy);
-                    foreach (var part in r)
+                    var offset = makeOffset(delta);
+                    foreach (var part in s)
                         part.Offset(offset);
                 }
 
-                y = MaxTop(r) + gap;
+                pos = stripMax(s) + gap;
             }
 
-            // Rebuild the parts list in row order.
             parts.Clear();
-            foreach (var r in rows)
-                parts.AddRange(r);
+            foreach (var s in strips)
+                parts.AddRange(s);
         }
 
         private static double MaxTop(List<Part> col)

OpenNest.Engine/Fill/PairFiller.cs

@@ -195,7 +195,7 @@ namespace OpenNest.Engine.Fill
                 if (pattern.Parts.Count == 0)
                     continue;
 
-                var engine = new FillLinear(workArea, partSpacing);
+                var engine = new FillLinear(workArea, partSpacing) { Label = "Pairs" };
                 foreach (var dir in new[] { NestDirection.Horizontal, NestDirection.Vertical })
                 {
                     if (!dedup.TryAdd(pattern.BoundingBox, workArea, dir))
@@ -321,7 +321,7 @@ namespace OpenNest.Engine.Fill
                 return cachedResult;
             }
 
-            var filler = new FillLinear(remnantBox, partSpacing);
+            var filler = new FillLinear(remnantBox, partSpacing) { Label = "Pairs-Remnant" };
             List<Part> parts = null;
 
             foreach (var angle in new[] { 0.0, Angle.HalfPI })

OpenNest.Engine/Fill/StripeFiller.cs

@@ -121,7 +121,7 @@ public class StripeFiller
         if (!_dedup.TryAdd(rotatedPattern.BoundingBox, workArea, primaryAxis))
             return null;
 
-        var stripeEngine = new FillLinear(stripeBox, spacing);
+        var stripeEngine = new FillLinear(stripeBox, spacing) { Label = "Stripe" };
         var stripeParts = stripeEngine.Fill(rotatedPattern, primaryAxis);
 
         if (stripeParts == null || stripeParts.Count == 0)
@@ -136,7 +136,7 @@ public class StripeFiller
         stripePattern.Parts.AddRange(stripeParts);
         stripePattern.UpdateBounds();
 
-        var gridEngine = new FillLinear(workArea, spacing);
+        var gridEngine = new FillLinear(workArea, spacing) { Label = "Stripe-Grid" };
         var gridParts = gridEngine.Fill(stripePattern, perpAxis);
 
         if (gridParts == null || gridParts.Count == 0)
@@ -244,7 +244,7 @@ public class StripeFiller
             return cachedResult;
         }
 
-        var filler = new FillLinear(remnantBox, spacing);
+        var filler = new FillLinear(remnantBox, spacing) { Label = "Stripe-Remnant" };
         List<Part> best = null;
 
         foreach (var angle in new[] { 0.0, Angle.HalfPI })
@@ -396,7 +396,7 @@ public class StripeFiller
             var stripeBox = axis == NestDirection.Horizontal
                 ? new Box(0, 0, sheetSpan, perpDim)
                 : new Box(0, 0, perpDim, sheetSpan);
-            var engine = new FillLinear(stripeBox, spacing);
+            var engine = new FillLinear(stripeBox, spacing) { Label = "Stripe-EstimateRow" };
             var filled = engine.Fill(rotated, axis);
             var n = filled?.Count ?? 0;
 
@@ -481,33 +481,6 @@ public class StripeFiller
         return axis == NestDirection.Horizontal ? box.Width : box.Length;
     }
 
-    /// <summary>
-    /// Checks if any pair of parts geometrically overlap. Uses bounding box
-    /// pre-filtering for performance, then falls back to shape intersection.
-    /// </summary>
-    private static bool HasOverlappingParts(List<Part> parts)
-    {
-        for (var i = 0; i < parts.Count; i++)
-        {
-            var b1 = parts[i].BoundingBox;
-
-            for (var j = i + 1; j < parts.Count; j++)
-            {
-                var b2 = parts[j].BoundingBox;
-
-                var overlapX = System.Math.Min(b1.Right, b2.Right)
-                             - System.Math.Max(b1.Left, b2.Left);
-                var overlapY = System.Math.Min(b1.Top, b2.Top)
-                             - System.Math.Max(b1.Bottom, b2.Bottom);
-
-                if (overlapX <= Tolerance.Epsilon || overlapY <= Tolerance.Epsilon)
-                    continue;
-
-                if (parts[i].Intersects(parts[j], out _))
-                    return true;
-            }
-        }
-
-        return false;
-    }
+    private static bool HasOverlappingParts(List<Part> parts) =>
+        FillHelpers.HasOverlappingParts(parts);
 }

OpenNest.Engine/NestEngineBase.cs

@@ -2,6 +2,7 @@ using OpenNest.Engine;
 using OpenNest.Engine.Fill;
 using OpenNest.Engine.Strategies;
 using OpenNest.Geometry;
+using OpenNest.Math;
 using System;
 using System.Collections.Generic;
 using System.Diagnostics;
@@ -275,8 +276,12 @@ namespace OpenNest
                 {
                     var box2 = parts[j].BoundingBox;
 
-                    if (box1.Right < box2.Left || box2.Right < box1.Left ||
-                        box1.Top < box2.Bottom || box2.Top < box1.Bottom)
+                    var overlapX = System.Math.Min(box1.Right, box2.Right)
+                                 - System.Math.Max(box1.Left, box2.Left);
+                    var overlapY = System.Math.Min(box1.Top, box2.Top)
+                                 - System.Math.Max(box1.Bottom, box2.Bottom);
+
+                    if (overlapX <= Tolerance.Epsilon || overlapY <= Tolerance.Epsilon)
                         continue;
 
                     List<Vector> pts;

OpenNest.Engine/RectanglePacking/FillBestFit.cs

@@ -36,52 +36,44 @@ namespace OpenNest.RectanglePacking
             throw new NotImplementedException();
         }
 
-        private Bin BestFitHorizontal(Item item)
+        private Bin BestFitHorizontal(Item item) => BestFitAxis(item, horizontal: true);
+
+        private Bin BestFitVertical(Item item) => BestFitAxis(item, horizontal: false);
+
+        private Bin BestFitAxis(Item item, bool horizontal)
         {
             var bin = Bin.Clone() as Bin;
 
-            int normalColumns = 0;
-            int rotateColumns = 0;
+            var primarySize = horizontal ? item.Width : item.Length;
+            var secondarySize = horizontal ? item.Length : item.Width;
+            var binPrimary = horizontal ? bin.Width : Bin.Length;
+            var binSecondary = horizontal ? bin.Length : Bin.Width;
 
-            if (!BestCombination.FindFrom2(item.Width, item.Length, bin.Width, out normalColumns, out rotateColumns))
+            if (!BestCombination.FindFrom2(primarySize, secondarySize, binPrimary, out var normalPrimary, out var rotatePrimary))
                 return bin;
 
-            var normalRows = (int)System.Math.Floor((bin.Length + Tolerance.Epsilon) / item.Length);
-            var rotateRows = (int)System.Math.Floor((bin.Length + Tolerance.Epsilon) / item.Width);
+            var normalSecondary = (int)System.Math.Floor((binSecondary + Tolerance.Epsilon) / secondarySize);
+            var rotateSecondary = (int)System.Math.Floor((binSecondary + Tolerance.Epsilon) / primarySize);
+
+            var (normalRows, normalCols) = horizontal
+                ? (normalSecondary, normalPrimary)
+                : (normalPrimary, normalSecondary);
+            var (rotateRows, rotateCols) = horizontal
+                ? (rotateSecondary, rotatePrimary)
+                : (rotatePrimary, rotateSecondary);
 
             item.Location = bin.Location;
 
-            bin.Items.AddRange(FillGrid(item, normalRows, normalColumns, int.MaxValue));
+            bin.Items.AddRange(FillGrid(item, normalRows, normalCols, int.MaxValue));
+
+            if (horizontal)
+                item.Location.X += item.Width * normalPrimary;
+            else
+                item.Location.Y += item.Length * normalPrimary;
 
-            item.Location.X += item.Width * normalColumns;
             item.Rotate();
 
-            bin.Items.AddRange(FillGrid(item, rotateRows, rotateColumns, int.MaxValue));
-
-            return bin;
-        }
-
-        private Bin BestFitVertical(Item item)
-        {
-            var bin = Bin.Clone() as Bin;
-
-            int normalRows = 0;
-            int rotateRows = 0;
-
-            if (!BestCombination.FindFrom2(item.Length, item.Width, Bin.Length, out normalRows, out rotateRows))
-                return bin;
-
-            var normalColumns = (int)System.Math.Floor((Bin.Width + Tolerance.Epsilon) / item.Width);
-            var rotateColumns = (int)System.Math.Floor((Bin.Width + Tolerance.Epsilon) / item.Length);
-
-            item.Location = bin.Location;
-
-            bin.Items.AddRange(FillGrid(item, normalRows, normalColumns, int.MaxValue));
-
-            item.Location.Y += item.Length * normalRows;
-            item.Rotate();
-
-            bin.Items.AddRange(FillGrid(item, rotateRows, rotateColumns, int.MaxValue));
+            bin.Items.AddRange(FillGrid(item, rotateRows, rotateCols, int.MaxValue));
 
             return bin;
         }

OpenNest.Engine/Strategies/ExtentsFillStrategy.cs

@@ -20,22 +20,10 @@ namespace OpenNest.Engine.Strategies
 
             var angles = new[] { bestRotation, bestRotation + Angle.HalfPI };
 
-            List<Part> best = null;
-            var comparer = context.Policy?.Comparer ?? new DefaultFillComparer();
-
-            foreach (var angle in angles)
-            {
-                context.Token.ThrowIfCancellationRequested();
-                var result = filler.Fill(context.Item.Drawing, angle,
-                    context.PlateNumber, context.Token, context.Progress);
-                if (result != null && result.Count > 0)
-                {
-                    if (best == null || comparer.IsBetter(result, best, context.WorkArea))
-                        best = result;
-                }
-            }
-
-            return best ?? new List<Part>();
+            return FillHelpers.BestOverAngles(context, angles,
+                angle => filler.Fill(context.Item.Drawing, angle,
+                    context.PlateNumber, context.Token, context.Progress),
+                NestPhase.Extents, "Extents");
         }
     }
 }

OpenNest.Engine/Strategies/FillHelpers.cs

@@ -109,5 +109,78 @@ namespace OpenNest.Engine.Strategies
             var fallback = fillFunc(other);
             return fallback ?? new List<Part>();
         }
+
+        /// <summary>
+        /// Sweeps a list of angles, calling fillAtAngle for each, and returns
+        /// the best result according to the context's comparer. Handles
+        /// cancellation and progress reporting.
+        /// </summary>
+        public static List<Part> BestOverAngles(
+            FillContext context,
+            IReadOnlyList<double> angles,
+            Func<double, List<Part>> fillAtAngle,
+            NestPhase phase,
+            string phaseLabel)
+        {
+            var workArea = context.WorkArea;
+            var comparer = context.Policy?.Comparer ?? new DefaultFillComparer();
+            List<Part> best = null;
+
+            for (var i = 0; i < angles.Count; i++)
+            {
+                context.Token.ThrowIfCancellationRequested();
+
+                var angle = angles[i];
+                var result = fillAtAngle(angle);
+                var angleDeg = Angle.ToDegrees(angle);
+
+                if (result != null && result.Count > 0)
+                {
+                    if (best == null || comparer.IsBetter(result, best, workArea))
+                        best = result;
+                }
+
+                NestEngineBase.ReportProgress(context.Progress, new ProgressReport
+                {
+                    Phase = phase,
+                    PlateNumber = context.PlateNumber,
+                    Parts = best,
+                    WorkArea = workArea,
+                    Description = $"{phaseLabel}: {i + 1}/{angles.Count} angles, {angleDeg:F0}° best = {best?.Count ?? 0} parts",
+                });
+            }
+
+            return best ?? new List<Part>();
+        }
+
+        /// <summary>
+        /// Checks if any pair of parts geometrically overlap. Uses bounding box
+        /// pre-filtering for performance, then falls back to shape intersection.
+        /// </summary>
+        internal static bool HasOverlappingParts(List<Part> parts)
+        {
+            for (var i = 0; i < parts.Count; i++)
+            {
+                var b1 = parts[i].BoundingBox;
+
+                for (var j = i + 1; j < parts.Count; j++)
+                {
+                    var b2 = parts[j].BoundingBox;
+
+                    var overlapX = System.Math.Min(b1.Right, b2.Right)
+                                 - System.Math.Max(b1.Left, b2.Left);
+                    var overlapY = System.Math.Min(b1.Top, b2.Top)
+                                 - System.Math.Max(b1.Bottom, b2.Bottom);
+
+                    if (overlapX <= Tolerance.Epsilon || overlapY <= Tolerance.Epsilon)
+                        continue;
+
+                    if (parts[i].Intersects(parts[j], out _))
+                        return true;
+                }
+            }
+
+            return false;
+        }
     }
 }

OpenNest.Engine/Strategies/LinearFillStrategy.cs

@@ -19,45 +19,28 @@ namespace OpenNest.Engine.Strategies
             var workArea = context.WorkArea;
             var comparer = context.Policy?.Comparer ?? new DefaultFillComparer();
             var preferred = context.Policy?.PreferredDirection;
-            List<Part> best = null;
 
-            for (var ai = 0; ai < angles.Count; ai++)
-            {
-                context.Token.ThrowIfCancellationRequested();
-
-                var angle = angles[ai];
-                var engine = new FillLinear(workArea, context.Plate.PartSpacing);
-
-                var result = FillHelpers.FillWithDirectionPreference(
-                    dir => engine.Fill(context.Item.Drawing, angle, dir),
-                    preferred, comparer, workArea);
-
-                var angleDeg = Angle.ToDegrees(angle);
-
-                if (result != null && result.Count > 0)
+            return FillHelpers.BestOverAngles(context, angles,
+                angle =>
                 {
-                    context.AngleResults.Add(new AngleResult
+                    var engine = new FillLinear(workArea, context.Plate.PartSpacing) { Label = "Linear" };
+                    var result = FillHelpers.FillWithDirectionPreference(
+                        dir => engine.Fill(context.Item.Drawing, angle, dir),
+                        preferred, comparer, workArea);
+
+                    if (result != null && result.Count > 0)
                     {
-                        AngleDeg = angleDeg,
-                        Direction = preferred ?? NestDirection.Horizontal,
-                        PartCount = result.Count
-                    });
+                        context.AngleResults.Add(new AngleResult
+                        {
+                            AngleDeg = Angle.ToDegrees(angle),
+                            Direction = preferred ?? NestDirection.Horizontal,
+                            PartCount = result.Count
+                        });
+                    }
 
-                    if (best == null || comparer.IsBetter(result, best, workArea))
-                        best = result;
-                }
-
-                NestEngineBase.ReportProgress(context.Progress, new ProgressReport
-                {
-                    Phase = NestPhase.Linear,
-                    PlateNumber = context.PlateNumber,
-                    Parts = best,
-                    WorkArea = workArea,
-                    Description = $"Linear: {ai + 1}/{angles.Count} angles, {angleDeg:F0}° best = {best?.Count ?? 0} parts",
-                });
-            }
-
-            return best ?? new List<Part>();
+                    return result;
+                },
+                NestPhase.Linear, "Linear");
         }
     }
 }

OpenNest.Tests/CollisionTests.cs

@@ -0,0 +1,218 @@
+using OpenNest.Geometry;
+using OpenNest.Math;
+using System.Collections.Generic;
+
+namespace OpenNest.Tests;
+
+public class CollisionTests
+{
+    /// Two unit squares overlapping by 0.5 in X.
+    /// Square A: (0,0)-(1,1), Square B: (0.5,0)-(1.5,1)
+    /// Expected overlap: (0.5,0)-(1,1), area = 0.5
+    [Fact]
+    public void Check_OverlappingSquares_ReturnsOverlapRegion()
+    {
+        var a = MakeSquare(0, 0, 1, 1);
+        var b = MakeSquare(0.5, 0, 1.5, 1);
+
+        var result = Collision.Check(a, b);
+
+        Assert.True(result.Overlaps);
+        Assert.True(result.OverlapArea > 0.49 && result.OverlapArea < 0.51);
+        Assert.NotEmpty(result.OverlapRegions);
+    }
+
+    /// Two squares that don't touch at all.
+    [Fact]
+    public void Check_NonOverlappingSquares_ReturnsNone()
+    {
+        var a = MakeSquare(0, 0, 1, 1);
+        var b = MakeSquare(5, 5, 6, 6);
+
+        var result = Collision.Check(a, b);
+
+        Assert.False(result.Overlaps);
+        Assert.Empty(result.OverlapRegions);
+        Assert.Equal(0, result.OverlapArea);
+    }
+
+    /// Two squares sharing an edge (touching but not overlapping).
+    [Fact]
+    public void Check_EdgeTouchingSquares_ReturnsNone()
+    {
+        var a = MakeSquare(0, 0, 1, 1);
+        var b = MakeSquare(1, 0, 2, 1);
+
+        var result = Collision.Check(a, b);
+
+        Assert.False(result.Overlaps);
+    }
+
+    /// One square fully inside another. Inner: (0.25,0.25)-(0.75,0.75), area = 0.25
+    [Fact]
+    public void Check_ContainedSquare_ReturnsInnerArea()
+    {
+        var a = MakeSquare(0, 0, 1, 1);
+        var b = MakeSquare(0.25, 0.25, 0.75, 0.75);
+
+        var result = Collision.Check(a, b);
+
+        Assert.True(result.Overlaps);
+        Assert.True(result.OverlapArea > 0.24 && result.OverlapArea < 0.26);
+    }
+
+    /// L-shaped concave polygon overlapping a square.
+    [Fact]
+    public void Check_ConcavePolygonOverlap_ReturnsOverlap()
+    {
+        // L-shape: 2x2 with a 1x1 notch cut from top-right
+        var lShape = new Polygon();
+        lShape.Vertices.Add(new Vector(0, 0));
+        lShape.Vertices.Add(new Vector(2, 0));
+        lShape.Vertices.Add(new Vector(2, 1));
+        lShape.Vertices.Add(new Vector(1, 1));
+        lShape.Vertices.Add(new Vector(1, 2));
+        lShape.Vertices.Add(new Vector(0, 2));
+        lShape.Close();
+        lShape.UpdateBounds();
+
+        // Square overlapping the notch area and bottom-right
+        var square = MakeSquare(1.5, 0, 2.5, 1.5);
+
+        var result = Collision.Check(lShape, square);
+
+        Assert.True(result.Overlaps);
+        // Overlap is 0.5 x 1.0 = 0.5 (the part of the square inside the L bottom-right)
+        Assert.True(result.OverlapArea > 0.49 && result.OverlapArea < 0.51);
+    }
+
+    /// <summary>
+    /// Square A has a hole. Square B overlaps only the hole area.
+    /// This should NOT be a collision — B fits inside A's cutout.
+    /// </summary>
+    [Fact]
+    public void Check_OverlapInsideHole_ReturnsNone()
+    {
+        var a = MakeSquare(0, 0, 4, 4);
+        var holeA = new List<Polygon> { MakeSquare(1, 1, 3, 3) };
+
+        // B fits entirely inside the hole
+        var b = MakeSquare(1.5, 1.5, 2.5, 2.5);
+
+        var result = Collision.Check(a, b, holesA: holeA);
+
+        Assert.False(result.Overlaps);
+    }
+
+    /// <summary>
+    /// Square A has a hole. Square B partially overlaps the hole and
+    /// partially overlaps solid material. Should still be a collision.
+    /// </summary>
+    [Fact]
+    public void Check_PartialOverlapWithHole_StillOverlaps()
+    {
+        var a = MakeSquare(0, 0, 4, 4);
+        var holeA = new List<Polygon> { MakeSquare(1, 1, 3, 3) };
+
+        // B extends beyond the hole into solid material
+        var b = MakeSquare(2, 2, 5, 5);
+
+        var result = Collision.Check(a, b, holesA: holeA);
+
+        // Hole subtraction uses a conservative approach (keeps partial overlaps),
+        // so we only verify that a collision is still detected for solid material.
+        Assert.True(result.Overlaps);
+    }
+
+    /// <summary>
+    /// HasOverlap with holes returns false when overlap is inside cutout.
+    /// </summary>
+    [Fact]
+    public void HasOverlap_InsideHole_ReturnsFalse()
+    {
+        var a = MakeSquare(0, 0, 4, 4);
+        var holeA = new List<Polygon> { MakeSquare(1, 1, 3, 3) };
+        var b = MakeSquare(1.5, 1.5, 2.5, 2.5);
+
+        Assert.False(Collision.HasOverlap(a, b, holesA: holeA));
+    }
+
+    [Fact]
+    public void CheckAll_MultiplePolygons_FindsAllOverlaps()
+    {
+        var a = MakeSquare(0, 0, 1, 1);
+        var b = MakeSquare(0.5, 0, 1.5, 1);  // overlaps A
+        var c = MakeSquare(5, 5, 6, 6);      // overlaps nobody
+
+        var results = Collision.CheckAll(new List<Polygon> { a, b, c });
+
+        Assert.Single(results);
+        Assert.True(results[0].Overlaps);
+    }
+
+    [Fact]
+    public void CheckAll_NoOverlaps_ReturnsEmpty()
+    {
+        var a = MakeSquare(0, 0, 1, 1);
+        var b = MakeSquare(3, 3, 4, 4);
+
+        var results = Collision.CheckAll(new List<Polygon> { a, b });
+
+        Assert.Empty(results);
+    }
+
+    [Fact]
+    public void HasAnyOverlap_WithOverlap_ReturnsTrue()
+    {
+        var a = MakeSquare(0, 0, 1, 1);
+        var b = MakeSquare(0.5, 0, 1.5, 1);
+
+        Assert.True(Collision.HasAnyOverlap(new List<Polygon> { a, b }));
+    }
+
+    [Fact]
+    public void HasAnyOverlap_NoOverlap_ReturnsFalse()
+    {
+        var a = MakeSquare(0, 0, 1, 1);
+        var b = MakeSquare(3, 3, 4, 4);
+
+        Assert.False(Collision.HasAnyOverlap(new List<Polygon> { a, b }));
+    }
+
+    [Fact]
+    public void Check_IdenticalSquares_FullOverlap()
+    {
+        var a = MakeSquare(0, 0, 1, 1);
+        var b = MakeSquare(0, 0, 1, 1);
+
+        var result = Collision.Check(a, b);
+
+        Assert.True(result.Overlaps);
+        Assert.True(result.OverlapArea > 0.99 && result.OverlapArea < 1.01);
+    }
+
+    [Fact]
+    public void HasAnyOverlap_SinglePolygon_ReturnsFalse()
+    {
+        var a = MakeSquare(0, 0, 1, 1);
+        Assert.False(Collision.HasAnyOverlap(new List<Polygon> { a }));
+    }
+
+    [Fact]
+    public void HasAnyOverlap_EmptyList_ReturnsFalse()
+    {
+        Assert.False(Collision.HasAnyOverlap(new List<Polygon>()));
+    }
+
+    private static Polygon MakeSquare(double left, double bottom, double right, double top)
+    {
+        var p = new Polygon();
+        p.Vertices.Add(new Vector(left, bottom));
+        p.Vertices.Add(new Vector(right, bottom));
+        p.Vertices.Add(new Vector(right, top));
+        p.Vertices.Add(new Vector(left, top));
+        p.Close();
+        p.UpdateBounds();
+        return p;
+    }
+}

OpenNest.Tests/EllipseConverterTests.cs

@@ -172,15 +172,15 @@ public class EllipseConverterTests
             var current = (Arc)result[i];
             var next = (Arc)result[i + 1];
             var gap = current.EndPoint().DistanceTo(next.StartPoint());
-            Assert.True(gap < 0.001,
-                $"Gap of {gap:F6} between arc {i} and arc {i + 1}");
+            Assert.True(gap < 1e-6,
+                $"Gap of {gap:E4} between arc {i} and arc {i + 1}");
         }
 
         var lastArc = (Arc)result[^1];
         var firstArc = (Arc)result[0];
         var closingGap = lastArc.EndPoint().DistanceTo(firstArc.StartPoint());
-        Assert.True(closingGap < 0.001,
-            $"Closing gap of {closingGap:F6}");
+        Assert.True(closingGap < 1e-6,
+            $"Closing gap of {closingGap:E4}");
     }
 
     [Fact]

OpenNest.Tests/StrategyOverlapTests.cs

@@ -107,4 +107,5 @@ public class StrategyOverlapTests
 
         Assert.Empty(failures);
     }
+
 }

OpenNest/Actions/Action.cs

@@ -1,4 +1,6 @@
 using OpenNest.Controls;
+using OpenNest.Geometry;
+using System.Drawing;
 
 namespace OpenNest.Actions
 {
@@ -11,6 +13,19 @@ namespace OpenNest.Actions
             this.plateView = plateView;
         }
 
+        protected RectangleF GetRectangle(Vector worldPt1, Vector worldPt2)
+        {
+            var pt1 = plateView.PointWorldToGraph(worldPt1);
+            var pt2 = plateView.PointWorldToGraph(worldPt2);
+
+            var x = pt1.X < pt2.X ? pt1.X : pt2.X;
+            var y = pt1.Y < pt2.Y ? pt1.Y : pt2.Y;
+            var w = System.Math.Abs(pt2.X - pt1.X);
+            var h = System.Math.Abs(pt2.Y - pt1.Y);
+
+            return new RectangleF(x, y, w, h);
+        }
+
         public virtual bool SurvivesPlateChange => false;
 
         public virtual void OnPlateChanged() { }

OpenNest/Actions/ActionSelect.cs

@@ -212,36 +212,7 @@ namespace OpenNest.Actions
             }
         }
 
-        private RectangleF GetRectangle()
-        {
-            var rect = new RectangleF();
-            var pt1 = plateView.PointWorldToGraph(Point1);
-            var pt2 = plateView.PointWorldToGraph(Point2);
-
-            if (pt1.X < pt2.X)
-            {
-                rect.X = pt1.X;
-                rect.Width = pt2.X - pt1.X;
-            }
-            else
-            {
-                rect.X = pt2.X;
-                rect.Width = pt1.X - pt2.X;
-            }
-
-            if (pt1.Y < pt2.Y)
-            {
-                rect.Y = pt1.Y;
-                rect.Height = pt2.Y - pt1.Y;
-            }
-            else
-            {
-                rect.Y = pt2.Y;
-                rect.Height = pt1.Y - pt2.Y;
-            }
-
-            return rect;
-        }
+        private RectangleF GetRectangle() => GetRectangle(Point1, Point2);
 
         public SelectionType SelectionType
         {

OpenNest/Actions/ActionZoomWindow.cs

@@ -166,36 +166,7 @@ namespace OpenNest.Actions
             plateView.Refresh();
         }
 
-        private RectangleF GetRectangle()
-        {
-            var rect = new RectangleF();
-            var pt1 = plateView.PointWorldToGraph(Point1);
-            var pt2 = plateView.PointWorldToGraph(Point2);
-
-            if (pt1.X < pt2.X)
-            {
-                rect.X = pt1.X;
-                rect.Width = pt2.X - pt1.X;
-            }
-            else
-            {
-                rect.X = pt2.X;
-                rect.Width = pt1.X - pt2.X;
-            }
-
-            if (pt1.Y < pt2.Y)
-            {
-                rect.Y = pt1.Y;
-                rect.Height = pt2.Y - pt1.Y;
-            }
-            else
-            {
-                rect.Y = pt2.Y;
-                rect.Height = pt1.Y - pt2.Y;
-            }
-
-            return rect;
-        }
+        private RectangleF GetRectangle() => GetRectangle(Point1, Point2);
 
         public enum Status
         {

OpenNest/Controls/FilterPanel.cs

@@ -74,7 +74,7 @@ namespace OpenNest.Controls
 
             var bendLinksPanel = new FlowLayoutPanel
             {
-                Dock = DockStyle.Bottom,
+                Dock = DockStyle.Top,
                 Height = 20,
                 FlowDirection = FlowDirection.LeftToRight,
                 WrapContents = false

OpenNest/Controls/PlateView.cs

@@ -1243,15 +1243,24 @@ namespace OpenNest.Controls
             var cts = new CancellationTokenSource();
             var progressForm = new NestProgressForm(cts, showPlateRow: false);
 
+            var previewPlate = new Plate(Plate.Size)
+            {
+                Quadrant = Plate.Quadrant,
+                PartSpacing = Plate.PartSpacing,
+                Thickness = Plate.Thickness,
+                Material = Plate.Material,
+            };
+            previewPlate.EdgeSpacing = Plate.EdgeSpacing;
+            progressForm.PreviewPlate = previewPlate;
+
             var progress = new Progress<NestProgress>(p =>
             {
                 progressForm.UpdateProgress(p);
 
                 if (p.IsOverallBest)
-                    SetStationaryParts(p.BestParts);
-                else
-                    SetActiveParts(p.BestParts);
+                    progressForm.UpdatePreview(p.BestParts);
 
+                SetActiveParts(p.BestParts);
                 ActiveWorkArea = p.ActiveWorkArea;
             });
 

OpenNest/Forms/MainForm.cs

@@ -905,15 +905,24 @@ namespace OpenNest.Forms
 
             var progressForm = new NestProgressForm(nestingCts, showPlateRow: true);
 
+            var previewPlate = new Plate(activeForm.PlateView.Plate.Size)
+            {
+                Quadrant = activeForm.PlateView.Plate.Quadrant,
+                PartSpacing = activeForm.PlateView.Plate.PartSpacing,
+                Thickness = activeForm.PlateView.Plate.Thickness,
+                Material = activeForm.PlateView.Plate.Material,
+            };
+            previewPlate.EdgeSpacing = activeForm.PlateView.Plate.EdgeSpacing;
+            progressForm.PreviewPlate = previewPlate;
+
             var progress = new Progress<NestProgress>(p =>
             {
                 progressForm.UpdateProgress(p);
 
                 if (p.IsOverallBest)
-                    activeForm.PlateView.SetStationaryParts(p.BestParts);
-                else
-                    activeForm.PlateView.SetActiveParts(p.BestParts);
+                    progressForm.UpdatePreview(p.BestParts);
 
+                activeForm.PlateView.SetActiveParts(p.BestParts);
                 activeForm.PlateView.ActiveWorkArea = p.ActiveWorkArea;
             });
 
@@ -939,8 +948,20 @@ namespace OpenNest.Forms
                         : activeForm.PlateView.Plate;
 
                     if (plate != activeForm.PlateView.Plate)
+                    {
                         activeForm.LoadLastPlate();
 
+                        var newPreviewPlate = new Plate(plate.Size)
+                        {
+                            Quadrant = plate.Quadrant,
+                            PartSpacing = plate.PartSpacing,
+                            Thickness = plate.Thickness,
+                            Material = plate.Material,
+                        };
+                        newPreviewPlate.EdgeSpacing = plate.EdgeSpacing;
+                        progressForm.PreviewPlate = newPreviewPlate;
+                    }
+
                     var anyPlaced = false;
 
                     var engine = NestEngineRegistry.Create(plate);

OpenNest/Forms/NestProgressForm.Designer.cs

@@ -41,6 +41,14 @@ namespace OpenNest.Forms
             buttonPanel = new System.Windows.Forms.FlowLayoutPanel();
             stopButton = new System.Windows.Forms.Button();
             acceptButton = new System.Windows.Forms.Button();
+            splitContainer = new System.Windows.Forms.SplitContainer();
+            statsPanel = new System.Windows.Forms.Panel();
+            previewPlateView = new OpenNest.Controls.PlateView();
+            ((System.ComponentModel.ISupportInitialize)splitContainer).BeginInit();
+            splitContainer.Panel1.SuspendLayout();
+            splitContainer.Panel2.SuspendLayout();
+            splitContainer.SuspendLayout();
+            statsPanel.SuspendLayout();
             resultsPanel.SuspendLayout();
             resultsTable.SuspendLayout();
             densityPanel.SuspendLayout();
@@ -48,19 +56,53 @@ namespace OpenNest.Forms
             statusTable.SuspendLayout();
             buttonPanel.SuspendLayout();
             SuspendLayout();
-            // 
+            //
+            // splitContainer
+            //
+            splitContainer.Dock = System.Windows.Forms.DockStyle.Fill;
+            splitContainer.FixedPanel = System.Windows.Forms.FixedPanel.Panel2;
+            splitContainer.Location = new System.Drawing.Point(0, 0);
+            splitContainer.Name = "splitContainer";
+            splitContainer.Panel1.Controls.Add(previewPlateView);
+            splitContainer.Panel2.Controls.Add(statsPanel);
+            splitContainer.Size = new System.Drawing.Size(750, 420);
+            splitContainer.SplitterDistance = 480;
+            splitContainer.TabIndex = 0;
+            //
+            // previewPlateView
+            //
+            previewPlateView.AllowDrop = false;
+            previewPlateView.Dock = System.Windows.Forms.DockStyle.Fill;
+            previewPlateView.Location = new System.Drawing.Point(0, 0);
+            previewPlateView.Name = "previewPlateView";
+            previewPlateView.Size = new System.Drawing.Size(480, 420);
+            previewPlateView.TabIndex = 0;
+            //
+            // statsPanel
+            //
+            statsPanel.AutoScroll = true;
+            statsPanel.Controls.Add(buttonPanel);
+            statsPanel.Controls.Add(statusPanel);
+            statsPanel.Controls.Add(resultsPanel);
+            statsPanel.Controls.Add(phaseStepper);
+            statsPanel.Dock = System.Windows.Forms.DockStyle.Fill;
+            statsPanel.Location = new System.Drawing.Point(0, 0);
+            statsPanel.Name = "statsPanel";
+            statsPanel.Size = new System.Drawing.Size(266, 420);
+            statsPanel.TabIndex = 0;
+            //
             // phaseStepper
-            // 
+            //
             phaseStepper.ActivePhase = null;
             phaseStepper.Dock = System.Windows.Forms.DockStyle.Top;
             phaseStepper.IsComplete = false;
             phaseStepper.Location = new System.Drawing.Point(0, 0);
             phaseStepper.Name = "phaseStepper";
-            phaseStepper.Size = new System.Drawing.Size(450, 60);
+            phaseStepper.Size = new System.Drawing.Size(266, 60);
             phaseStepper.TabIndex = 0;
-            // 
+            //
             // resultsPanel
-            // 
+            //
             resultsPanel.BackColor = System.Drawing.Color.White;
             resultsPanel.Controls.Add(resultsTable);
             resultsPanel.Controls.Add(resultsHeader);
@@ -69,11 +111,11 @@ namespace OpenNest.Forms
             resultsPanel.Margin = new System.Windows.Forms.Padding(10, 4, 10, 4);
             resultsPanel.Name = "resultsPanel";
             resultsPanel.Padding = new System.Windows.Forms.Padding(14, 10, 14, 10);
-            resultsPanel.Size = new System.Drawing.Size(450, 120);
+            resultsPanel.Size = new System.Drawing.Size(266, 120);
             resultsPanel.TabIndex = 1;
-            // 
+            //
             // resultsTable
-            // 
+            //
             resultsTable.AutoSize = true;
             resultsTable.ColumnCount = 2;
             resultsTable.ColumnStyles.Add(new System.Windows.Forms.ColumnStyle(System.Windows.Forms.SizeType.Absolute, 90F));
@@ -91,11 +133,11 @@ namespace OpenNest.Forms
             resultsTable.RowStyles.Add(new System.Windows.Forms.RowStyle());
             resultsTable.RowStyles.Add(new System.Windows.Forms.RowStyle());
             resultsTable.RowStyles.Add(new System.Windows.Forms.RowStyle());
-            resultsTable.Size = new System.Drawing.Size(422, 69);
+            resultsTable.Size = new System.Drawing.Size(238, 69);
             resultsTable.TabIndex = 1;
-            // 
+            //
             // partsLabel
-            // 
+            //
             partsLabel.AutoSize = true;
             partsLabel.Font = new System.Drawing.Font("Segoe UI", 9.75F, System.Drawing.FontStyle.Bold);
             partsLabel.ForeColor = System.Drawing.Color.FromArgb(51, 51, 51);
@@ -105,9 +147,9 @@ namespace OpenNest.Forms
             partsLabel.Size = new System.Drawing.Size(43, 17);
             partsLabel.TabIndex = 0;
             partsLabel.Text = "Parts:";
-            // 
+            //
             // partsValue
-            // 
+            //
             partsValue.AutoSize = true;
             partsValue.Font = new System.Drawing.Font("Consolas", 9.75F);
             partsValue.Location = new System.Drawing.Point(90, 3);
@@ -115,10 +157,10 @@ namespace OpenNest.Forms
             partsValue.Name = "partsValue";
             partsValue.Size = new System.Drawing.Size(13, 15);
             partsValue.TabIndex = 1;
-            partsValue.Text = "�";
-            // 
+            partsValue.Text = "\u2014";
+            //
             // densityLabel
-            // 
+            //
             densityLabel.AutoSize = true;
             densityLabel.Font = new System.Drawing.Font("Segoe UI", 9.75F, System.Drawing.FontStyle.Bold);
             densityLabel.ForeColor = System.Drawing.Color.FromArgb(51, 51, 51);
@@ -128,21 +170,21 @@ namespace OpenNest.Forms
             densityLabel.Size = new System.Drawing.Size(59, 17);
             densityLabel.TabIndex = 2;
             densityLabel.Text = "Density:";
-            // 
+            //
             // densityPanel
-            // 
+            //
             densityPanel.AutoSize = true;
             densityPanel.Controls.Add(densityValue);
             densityPanel.Controls.Add(densityBar);
             densityPanel.Location = new System.Drawing.Point(90, 23);
             densityPanel.Margin = new System.Windows.Forms.Padding(0);
             densityPanel.Name = "densityPanel";
-            densityPanel.Size = new System.Drawing.Size(262, 21);
+            densityPanel.Size = new System.Drawing.Size(148, 21);
             densityPanel.TabIndex = 3;
             densityPanel.WrapContents = false;
-            // 
+            //
             // densityValue
-            // 
+            //
             densityValue.AutoSize = true;
             densityValue.Font = new System.Drawing.Font("Consolas", 9.75F);
             densityValue.Location = new System.Drawing.Point(0, 3);
@@ -150,19 +192,19 @@ namespace OpenNest.Forms
             densityValue.Name = "densityValue";
             densityValue.Size = new System.Drawing.Size(13, 15);
             densityValue.TabIndex = 0;
-            densityValue.Text = "�";
-            // 
+            densityValue.Text = "\u2014";
+            //
             // densityBar
-            // 
+            //
             densityBar.Location = new System.Drawing.Point(21, 5);
             densityBar.Margin = new System.Windows.Forms.Padding(0, 5, 0, 0);
             densityBar.Name = "densityBar";
-            densityBar.Size = new System.Drawing.Size(241, 8);
+            densityBar.Size = new System.Drawing.Size(127, 8);
             densityBar.TabIndex = 1;
             densityBar.Value = 0D;
-            // 
+            //
             // nestedAreaLabel
-            // 
+            //
             nestedAreaLabel.AutoSize = true;
             nestedAreaLabel.Font = new System.Drawing.Font("Segoe UI", 9.75F, System.Drawing.FontStyle.Bold);
             nestedAreaLabel.ForeColor = System.Drawing.Color.FromArgb(51, 51, 51);
@@ -172,9 +214,9 @@ namespace OpenNest.Forms
             nestedAreaLabel.Size = new System.Drawing.Size(55, 17);
             nestedAreaLabel.TabIndex = 4;
             nestedAreaLabel.Text = "Nested:";
-            // 
+            //
             // nestedAreaValue
-            // 
+            //
             nestedAreaValue.AutoSize = true;
             nestedAreaValue.Font = new System.Drawing.Font("Consolas", 9.75F);
             nestedAreaValue.Location = new System.Drawing.Point(90, 49);
@@ -182,10 +224,10 @@ namespace OpenNest.Forms
             nestedAreaValue.Name = "nestedAreaValue";
             nestedAreaValue.Size = new System.Drawing.Size(13, 15);
             nestedAreaValue.TabIndex = 5;
-            nestedAreaValue.Text = "�";
-            // 
+            nestedAreaValue.Text = "\u2014";
+            //
             // resultsHeader
-            // 
+            //
             resultsHeader.AutoSize = true;
             resultsHeader.Dock = System.Windows.Forms.DockStyle.Top;
             resultsHeader.Font = new System.Drawing.Font("Segoe UI", 10.5F, System.Drawing.FontStyle.Bold);
@@ -196,9 +238,9 @@ namespace OpenNest.Forms
             resultsHeader.Size = new System.Drawing.Size(65, 23);
             resultsHeader.TabIndex = 0;
             resultsHeader.Text = "RESULTS";
-            // 
+            //
             // statusPanel
-            // 
+            //
             statusPanel.BackColor = System.Drawing.Color.White;
             statusPanel.Controls.Add(statusTable);
             statusPanel.Controls.Add(statusHeader);
@@ -206,11 +248,11 @@ namespace OpenNest.Forms
             statusPanel.Location = new System.Drawing.Point(0, 180);
             statusPanel.Name = "statusPanel";
             statusPanel.Padding = new System.Windows.Forms.Padding(14, 10, 14, 10);
-            statusPanel.Size = new System.Drawing.Size(450, 115);
+            statusPanel.Size = new System.Drawing.Size(266, 115);
             statusPanel.TabIndex = 2;
-            // 
+            //
             // statusTable
-            // 
+            //
             statusTable.AutoSize = true;
             statusTable.ColumnCount = 2;
             statusTable.ColumnStyles.Add(new System.Windows.Forms.ColumnStyle(System.Windows.Forms.SizeType.Absolute, 90F));
@@ -228,11 +270,11 @@ namespace OpenNest.Forms
             statusTable.RowStyles.Add(new System.Windows.Forms.RowStyle());
             statusTable.RowStyles.Add(new System.Windows.Forms.RowStyle());
             statusTable.RowStyles.Add(new System.Windows.Forms.RowStyle());
-            statusTable.Size = new System.Drawing.Size(422, 69);
+            statusTable.Size = new System.Drawing.Size(238, 69);
             statusTable.TabIndex = 1;
-            // 
+            //
             // plateLabel
-            // 
+            //
             plateLabel.AutoSize = true;
             plateLabel.Font = new System.Drawing.Font("Segoe UI", 9.75F, System.Drawing.FontStyle.Bold);
             plateLabel.ForeColor = System.Drawing.Color.FromArgb(51, 51, 51);
@@ -242,9 +284,9 @@ namespace OpenNest.Forms
             plateLabel.Size = new System.Drawing.Size(43, 17);
             plateLabel.TabIndex = 0;
             plateLabel.Text = "Plate:";
-            // 
+            //
             // plateValue
-            // 
+            //
             plateValue.AutoSize = true;
             plateValue.Font = new System.Drawing.Font("Consolas", 9.75F);
             plateValue.Location = new System.Drawing.Point(90, 3);
@@ -252,10 +294,10 @@ namespace OpenNest.Forms
             plateValue.Name = "plateValue";
             plateValue.Size = new System.Drawing.Size(13, 15);
             plateValue.TabIndex = 1;
-            plateValue.Text = "�";
-            // 
+            plateValue.Text = "\u2014";
+            //
             // elapsedLabel
-            // 
+            //
             elapsedLabel.AutoSize = true;
             elapsedLabel.Font = new System.Drawing.Font("Segoe UI", 9.75F, System.Drawing.FontStyle.Bold);
             elapsedLabel.ForeColor = System.Drawing.Color.FromArgb(51, 51, 51);
@@ -265,9 +307,9 @@ namespace OpenNest.Forms
             elapsedLabel.Size = new System.Drawing.Size(59, 17);
             elapsedLabel.TabIndex = 2;
             elapsedLabel.Text = "Elapsed:";
-            // 
+            //
             // elapsedValue
-            // 
+            //
             elapsedValue.AutoSize = true;
             elapsedValue.Font = new System.Drawing.Font("Consolas", 9.75F);
             elapsedValue.Location = new System.Drawing.Point(90, 26);
@@ -276,9 +318,9 @@ namespace OpenNest.Forms
             elapsedValue.Size = new System.Drawing.Size(35, 15);
             elapsedValue.TabIndex = 3;
             elapsedValue.Text = "0:00";
-            // 
+            //
             // descriptionLabel
-            // 
+            //
             descriptionLabel.AutoSize = true;
             descriptionLabel.Font = new System.Drawing.Font("Segoe UI", 9.75F, System.Drawing.FontStyle.Bold);
             descriptionLabel.ForeColor = System.Drawing.Color.FromArgb(51, 51, 51);
@@ -288,9 +330,9 @@ namespace OpenNest.Forms
             descriptionLabel.Size = new System.Drawing.Size(49, 17);
             descriptionLabel.TabIndex = 4;
             descriptionLabel.Text = "Detail:";
-            // 
+            //
             // descriptionValue
-            // 
+            //
             descriptionValue.AutoSize = true;
             descriptionValue.Font = new System.Drawing.Font("Segoe UI", 9.75F);
             descriptionValue.Location = new System.Drawing.Point(90, 49);
@@ -298,10 +340,10 @@ namespace OpenNest.Forms
             descriptionValue.Name = "descriptionValue";
             descriptionValue.Size = new System.Drawing.Size(20, 17);
             descriptionValue.TabIndex = 5;
-            descriptionValue.Text = "�";
-            // 
+            descriptionValue.Text = "\u2014";
+            //
             // statusHeader
-            // 
+            //
             statusHeader.AutoSize = true;
             statusHeader.Dock = System.Windows.Forms.DockStyle.Top;
             statusHeader.Font = new System.Drawing.Font("Segoe UI", 10.5F, System.Drawing.FontStyle.Bold);
@@ -312,9 +354,9 @@ namespace OpenNest.Forms
             statusHeader.Size = new System.Drawing.Size(59, 23);
             statusHeader.TabIndex = 0;
             statusHeader.Text = "STATUS";
-            // 
+            //
             // buttonPanel
-            // 
+            //
             buttonPanel.AutoSize = true;
             buttonPanel.Controls.Add(stopButton);
             buttonPanel.Controls.Add(acceptButton);
@@ -323,14 +365,14 @@ namespace OpenNest.Forms
             buttonPanel.Location = new System.Drawing.Point(0, 295);
             buttonPanel.Name = "buttonPanel";
             buttonPanel.Padding = new System.Windows.Forms.Padding(9, 6, 9, 6);
-            buttonPanel.Size = new System.Drawing.Size(450, 45);
+            buttonPanel.Size = new System.Drawing.Size(266, 45);
             buttonPanel.TabIndex = 3;
-            // 
+            //
             // stopButton
-            // 
+            //
             stopButton.Enabled = false;
             stopButton.Font = new System.Drawing.Font("Segoe UI", 9.75F);
-            stopButton.Location = new System.Drawing.Point(339, 9);
+            stopButton.Location = new System.Drawing.Point(155, 9);
             stopButton.Margin = new System.Windows.Forms.Padding(0, 3, 0, 3);
             stopButton.Name = "stopButton";
             stopButton.Size = new System.Drawing.Size(93, 27);
@@ -338,12 +380,12 @@ namespace OpenNest.Forms
             stopButton.Text = "Stop";
             stopButton.UseVisualStyleBackColor = true;
             stopButton.Click += StopButton_Click;
-            // 
+            //
             // acceptButton
-            // 
+            //
             acceptButton.Enabled = false;
             acceptButton.Font = new System.Drawing.Font("Segoe UI", 9.75F);
-            acceptButton.Location = new System.Drawing.Point(246, 9);
+            acceptButton.Location = new System.Drawing.Point(56, 9);
             acceptButton.Margin = new System.Windows.Forms.Padding(6, 3, 0, 3);
             acceptButton.Name = "acceptButton";
             acceptButton.Size = new System.Drawing.Size(93, 27);
@@ -351,23 +393,27 @@ namespace OpenNest.Forms
             acceptButton.Text = "Accept";
             acceptButton.UseVisualStyleBackColor = true;
             acceptButton.Click += AcceptButton_Click;
-            // 
+            //
             // NestProgressForm
-            // 
+            //
             AutoScaleDimensions = new System.Drawing.SizeF(7F, 15F);
             AutoScaleMode = System.Windows.Forms.AutoScaleMode.Font;
-            ClientSize = new System.Drawing.Size(450, 345);
-            Controls.Add(buttonPanel);
-            Controls.Add(statusPanel);
-            Controls.Add(resultsPanel);
-            Controls.Add(phaseStepper);
-            FormBorderStyle = System.Windows.Forms.FormBorderStyle.FixedToolWindow;
+            ClientSize = new System.Drawing.Size(750, 420);
+            Controls.Add(splitContainer);
+            FormBorderStyle = System.Windows.Forms.FormBorderStyle.SizableToolWindow;
             MaximizeBox = false;
             MinimizeBox = false;
+            MinimumSize = new System.Drawing.Size(550, 380);
             Name = "NestProgressForm";
             ShowInTaskbar = false;
             StartPosition = System.Windows.Forms.FormStartPosition.CenterParent;
             Text = "Nesting Progress";
+            splitContainer.Panel1.ResumeLayout(false);
+            splitContainer.Panel2.ResumeLayout(false);
+            ((System.ComponentModel.ISupportInitialize)splitContainer).EndInit();
+            splitContainer.ResumeLayout(false);
+            statsPanel.ResumeLayout(false);
+            statsPanel.PerformLayout();
             resultsPanel.ResumeLayout(false);
             resultsPanel.PerformLayout();
             resultsTable.ResumeLayout(false);
@@ -380,7 +426,6 @@ namespace OpenNest.Forms
             statusTable.PerformLayout();
             buttonPanel.ResumeLayout(false);
             ResumeLayout(false);
-            PerformLayout();
         }
 
         #endregion
@@ -409,5 +454,8 @@ namespace OpenNest.Forms
         private System.Windows.Forms.FlowLayoutPanel buttonPanel;
         private System.Windows.Forms.Button acceptButton;
         private System.Windows.Forms.Button stopButton;
+        private System.Windows.Forms.SplitContainer splitContainer;
+        private System.Windows.Forms.Panel statsPanel;
+        private Controls.PlateView previewPlateView;
     }
 }

OpenNest/Forms/NestProgressForm.cs

@@ -27,11 +27,23 @@ namespace OpenNest.Forms
 
         public bool Accepted { get; private set; }
 
+        public Plate PreviewPlate
+        {
+            get => previewPlateView.Plate;
+            set
+            {
+                previewPlateView.Plate = value;
+                previewPlateView.ZoomToFit();
+            }
+        }
+
         public NestProgressForm(CancellationTokenSource cts, bool showPlateRow = true)
         {
             this.cts = cts;
             InitializeComponent();
 
+            previewPlateView.AllowSelect = false;
+
             if (!showPlateRow)
             {
                 plateLabel.Visible = false;
@@ -59,23 +71,40 @@ namespace OpenNest.Forms
             }
 
             phaseStepper.ActivePhase = progress.Phase;
-
             SetValueWithFlash(plateValue, progress.PlateNumber.ToString());
-            SetValueWithFlash(partsValue, progress.BestPartCount.ToString());
 
-            var densityText = progress.BestDensity.ToString("P1");
-            var densityFlashColor = GetDensityColor(progress.BestDensity);
-            SetValueWithFlash(densityValue, densityText, densityFlashColor);
-            densityBar.Value = progress.BestDensity;
+            if (progress.IsOverallBest)
+            {
+                SetValueWithFlash(partsValue, progress.BestPartCount.ToString());
 
-            SetValueWithFlash(nestedAreaValue,
-                $"{progress.NestedWidth:F1} x {progress.NestedLength:F1} ({progress.NestedArea:F1} sq in)");
+                var densityText = progress.BestDensity.ToString("P1");
+                var densityFlashColor = GetDensityColor(progress.BestDensity);
+                SetValueWithFlash(densityValue, densityText, densityFlashColor);
+                densityBar.Value = progress.BestDensity;
+
+                SetValueWithFlash(nestedAreaValue,
+                    $"{progress.NestedWidth:F1} x {progress.NestedLength:F1} ({progress.NestedArea:F1} sq in)");
+            }
 
             descriptionValue.Text = !string.IsNullOrEmpty(progress.Description)
                 ? progress.Description
                 : progress.Phase.DisplayName();
         }
 
+        public void UpdatePreview(List<Part> bestParts)
+        {
+            if (IsDisposed || !IsHandleCreated)
+                return;
+
+            var plate = previewPlateView.Plate;
+            plate.Parts.Clear();
+
+            foreach (var part in bestParts)
+                plate.Parts.Add((Part)part.Clone());
+
+            previewPlateView.ZoomToFit();
+        }
+
         public void ShowCompleted()
         {
             if (IsDisposed || !IsHandleCreated)
@@ -135,6 +164,8 @@ namespace OpenNest.Forms
             if (!cts.IsCancellationRequested)
                 cts.Cancel();
 
+            previewPlateView.Dispose();
+
             base.OnFormClosing(e);
         }
 

OpenNest/Forms/PatternTileForm.cs

@@ -220,7 +220,7 @@ namespace OpenNest.Forms
                 return;
 
             var workArea = new Box(0, 0, plateSize.Length, plateSize.Width);
-            var filler = new FillLinear(workArea, PartSpacing);
+            var filler = new FillLinear(workArea, PartSpacing) { Label = "PatternTile-H" };
 
             var hParts = filler.Fill(pattern, NestDirection.Horizontal);
             foreach (var part in hParts)
@@ -228,7 +228,7 @@ namespace OpenNest.Forms
             hLabel.Text = $"Horizontal — {hParts.Count} parts";
             hPreview.ZoomToFit();
 
-            var vFiller = new FillLinear(workArea, PartSpacing);
+            var vFiller = new FillLinear(workArea, PartSpacing) { Label = "PatternTile-V" };
             var vParts = vFiller.Fill(pattern, NestDirection.Vertical);
             foreach (var part in vParts)
                 vPreview.Plate.Parts.Add(part);
@@ -328,7 +328,7 @@ namespace OpenNest.Forms
             if (pattern == null)
                 return;
 
-            var filler = new FillLinear(new Box(0, 0, plateSize.Length, plateSize.Width), PartSpacing);
+            var filler = new FillLinear(new Box(0, 0, plateSize.Length, plateSize.Width), PartSpacing) { Label = "PatternTile-Apply" };
             var tiledParts = filler.Fill(pattern, applyDirection);
 
             Result = new PatternTileResult