OpenNest/docs/geometry/visual-overlap-check.md

Visual material-overlap check

Desktop use

Choose View > Overlap Check > Check Active Plate to check committed parts on this plate. Shared material is shaded red/magenta without changing the nest, selection, cutting paths, or export behavior. Cutoffs and temporary preview parts are excluded. Cancel Check discards the running request. Display > Off / Areas / Markers / Both changes visibility without rerunning analysis. Areas is the default; rechecking preserves a visible mode, while checking from Off shows Areas. Clamp overlaps are shown as part/clamp findings with the clamp ID in hover details; clamps are not selectable parts and are not added to quantity or machining. A clamp edit invalidates the diagnostic and schedules a fresh check. Display preferences belong to the current document and are not saved.

Markers and Both show fixed-screen-size, DPI-scaled pair crosshairs with a contrasting halo. Labels such as 1/3 identify the two plate sequence positions at capture time, including gaps occupied by cutoffs. Hover near a marker to see captured names, approximate shared area in in² or mm², and marker coordinates in the same linear units. Units are captured with the request; hover does not relabel an old report from live settings. Nearby/coincident markers show all matching pairs in sequence order. If details exceed the view, the tooltip wraps and pages them with a Page x/y hint: keep the pointer near the marker and use plain PageUp / PageDown while PlateView has focus. Long individual details continue across pages without truncation; an impossibly small viewport asks you to enlarge it. These keys act only while a multipage diagnostic tooltip is visible; wheel zoom, modified keys, selection clicks, and dragging are unchanged. Small positive areas use significant-figure formatting rather than rounding to zero. Selection and dragging remain ordinary plate operations, not overlay interactions.

A persistent label distinguishes unchecked, checking, current, incomplete, stale, canceled, and failed checks. Only a completed, current, fully checked report can say No material overlaps detected. An incomplete check retains known overlaps and states how many distinct parts could not be checked. Pair counts are not fragment counts. This diagnostic checks shared material, not minimum spacing, plate edges, or cutting-path crossings.

In a nest window the active plate is checked automatically. Any layout edit (add, remove, reorder, move, rotate, fill) invalidates the full report and shows Overlaps: check pending…, but highlights for unchanged pairs remain visible. Only highlights involving changed ordered input slots are removed; once the layout has been unchanged for 0.5 s and no mouse button, modal dialog, or fill progress window is active, the check reruns. Automatic results appear only in the canvas label, so the status bar keeps the last command's message, and an automatic check keeps Display > Off rather than switching to Areas. Rechecks are incremental: drawing material is prepared once and reused, and pairs whose two parts have not moved reuse the previous result, so only the moved parts' neighbors are clipped again. Canceling a check is respected until the layout changes again, and a failed layout is not retried until it changes. Check Active Plate remains available and always runs at once.

Plate changes reset the check. Pan, zoom, selection, and display changes do not rerun geometry. Drawing-editor loading invalidates before loading (dropping cached material), even if the dialog is later canceled. There is no check during export.

Analysis API

OpenNest.Diagnostics.PlateOverlapAnalyzer in OpenNest.Core checks a group of placed parts and returns the shared material for each overlapping pair as connected islands. It clips with Clipper2. Existing Part.Intersects, PartOverlapChecker, Plate.HasOverlappingParts, engine validators, and CLI entry points are unchanged and still use the hand-written Collision kernel (its GPU port is on hold).

Synchronous use

using OpenNest.Diagnostics;

var report = PlateOverlapAnalyzer.Analyze(parts, cancellationToken);
var areas = report.Pairs.SelectMany(pair => pair.Regions).ToList();

foreach (var pair in report.Pairs)
{
    // IDs are zero-based positions in the original input list, including skipped cutoffs.
    Console.WriteLine($"{pair.PartAId} / {pair.PartBId}: {pair.Area}, marker {pair.Marker}");
    foreach (var region in pair.Regions)
    {
        // region.Vertices: closed, read-only, counterclockwise world-coordinate outline
        // region.Holes: closed, read-only, clockwise hole rings inside that outline
        // region.Area: positive net shared material area, in model units squared
    }
}

// An empty list alone does not mean the whole group was checked successfully.
if (!report.IsComplete)
    foreach (var issue in report.Issues)
        Console.WriteLine($"Uncheckable input/pair {issue.PartAId} / {issue.PartBId}: {issue.Message}");

Pairs is ordered by (PartAId, PartBId), with PartAId < PartBId. Drawing names are captured as labels, not used as identity. Repeated instances and different drawings with the same name remain distinct. Callers should pass each physical instance once; duplicate input entries are distinct positions in the group. pair.Bounds returns a fresh world-coordinate bounding box; collections and vertices cannot mutate the snapshot, report, or live geometry.

Capture once, analyze off-thread

// UI thread, while the plate and drawings are stable:
var snapshot = PlateOverlapAnalyzer.CapturePlate(plate, cancellationToken: cancellationToken);

// Worker thread, no access to live Part/Drawing/Program objects:
var report = await Task.Run(
    () => PlateOverlapAnalyzer.Analyze(snapshot, cancellationToken),
    cancellationToken);

Capture converts each distinct clean source program by reference identity once into owned entities, including expanded shared hole-subprogram calls, and copies input IDs, names, locations, and baseline-adjusted rotations. This is intentionally not a Program.Clone dependency: conversion itself creates fresh geometry without mutating the source or re-aligning shared subprograms. Capture has synchronous conversion cost; callers must not mutate inputs while capture runs.

Analysis clones captured entities before chaining, prepares polygons once per source, then prepares each pose. An X-sorted bounds sweep prunes separated pairs. Each candidate pair is intersected once with Clipper2: each operand is its outline minus the union of its holes (outline positive, holes negative, positive fill rule). Pairs are rebased near the origin and rounded to a 1e-8 model-unit grid for clipping, then restored to world coordinates. A coordinate more than 1e9 units from the pair's origin, or a nonfinite one, makes that pair incomplete rather than clear. Area calculation uses translated-origin products to avoid cancellation far from the origin. Snapshots can be reused and analyzed concurrently. Callers own freshness checks and must not publish results after geometry changes or after a newer request supersedes them.

Cancellation throws OperationCanceledException; it never returns a partial all-clear. Checks occur between source/pose preparation, validation loops, and candidate pairs, and before return. An individual conversion, polygonization, or Clipper2 intersection is not internally interruptible.

Material contract

• Material comes from Part.BaseDrawing.Program, transformed by part.Rotation - drawing.Program.Rotation, then part.Location. Applied or restored lead-ins, lead-outs, and tabs in Part.Program do not redefine material.
• Cutoff parts are skipped. Scribe, rapid, lead-in, and lead-out layers in the clean source do not define material; ordinary cut/default/display contours do.
• The caller chooses the group. Preview parts are not intrinsically distinguishable from committed parts here; a PlateView caller must supply committed parts only.
• Valid material has one simple closed outer contour and strictly internal, mutually disjoint holes. Open, empty, degenerate, self-intersecting, nonfinite, disconnected-outer, touching-hole, intersecting-hole, or nested-island geometry produces an issue. Native contour intersections are checked before polygonal containment, so sampling cannot hide a circular-hole crossing or tangency. A gap above Tolerance.Epsilon is not silently welded closed. One self-contact is recognized: a seam overcut, where the last cut runs past the contour's own start along its first cut and a straight jog returns to the start (converted nests carry another CAM system's overcut this way). It encloses no area and is trimmed from the analyzer's owned copy, never from the drawing; see cutting dependencies. Open cut marks are conservatively uncheckable; mark them as Scribe instead.
• Some valid curved geometry, such as sub-chord-width thin rings whose sampled contours cross, is uncheckable at this fixed tolerance and returns incomplete rather than clear. No automatic healing or adaptive refinement is performed. Poses that collapse edges or materially change area through floating-point rounding are also incomplete, even when all coordinates remain finite.
• Expected geometry failures produce issues with original input indices and preserve overlaps found among other valid parts. Unexpected failures propagate. A report with any issue has IsComplete == false, even if Pairs is empty.
• No part, drawing, quantity, pose, cutting state, or selection is modified.

For a full plate, PlateOverlapAnalyzer.CapturePlate(plate) also captures active clamps and nominal manual cut-off definitions. CutOffClampFindings is a separate list of zero-area line/rectangle contacts, not Pairs or material overlap. The view marks these with an X and a cut-off number/clamp ID, including contacts whose current regenerated program has been trimmed. Removed clamps produce no contact. Zones are mapped from the sheet's lower-left frame into the parts' quadrant frame; a malformed zone fails the check rather than being skipped. Editing definitions, sheet size/quadrant or zones stales the result (including part/clamp findings, because a size or quadrant change moves the zones); posting runs its own fresh check with per-attempt consent.

Interpretation and limits

Regions are connected islands of shared material. Each has a counterclockwise outline and clockwise Holes; an island can also sit inside a hole that both parts' holes enclose together. Fill outlines and holes in one nonzero-winding path so holes stay empty. Areas within one pair may be summed. Areas across pairs are not a union: three coincident parts produce three overlapping pairs, so summing all pair areas double-counts shared plate locations.

pair.Centroid is the true area-weighted center of every shared-material island for that pair, after hole subtraction. It is not an average of crossings or vertices. For a disconnected, holed or concave overlap it can lie outside the red material (between two patches, in a hole, or inside a curve).

pair.Marker is where markers, hover hit testing and cutting-inspection rings go: a point on the shared material, inside the pair's largest island. It is that island's pole of inaccessibility (PolyLabel), searched to a tenth of the island's area/perimeter with a budget of 4096 distance evaluations. If that bounded search does not land inside (a long thin sliver), the marker is the midpoint of the widest interior run of a horizontal scan line through the island, placed between vertex heights. There is one marker per pair, not per island: a second patch has shading but no crosshair.

A clamp narrower than the 0.001 chord tolerance is judged tolerance-free against finely re-read material rather than by Clipper2. Any material entering it is reported, even below the area threshold. The finding's region is then the whole clamp rectangle, and its centroid and marker are the clamp's centre: within half the clamp's size (under 0.0005) of the material, though not necessarily on it.

PolygonAreaMoments evaluates signed moments about local origins. The analyzer subtracts each island's hole moments from its outline's (TrySubtract), then combines the islands with positive area weights (TryCombine), on rebased coordinates before adding the world origin back. Invalid, degenerate, or nonfinite moments produce an incomplete pair issue, not a marker at zero. Curved-outline centroids inherit the polygonization approximation.

Full containment and coincident parts are detected without relying on crossing points. Edge/corner contact with no positive shared material is not overlap. There are no spacing offsets, plate-edge checks, cut-path crossing checks, automatic repairs, export blocks, or machining-validity guarantees.

Arc/circle flattening uses a chord tolerance of 0.001 model units (also exposed as report.ChordTolerance). Curved overlaps and topology are therefore polygonal approximations. A pair is reported when its total shared area exceeds Tolerance.Epsilon (0.00001 square units). Contact and rounding dust below that are not overlap. The engine's Collision kernel instead drops each convex fragment at or below that area, so a sliver it splits into small fragments can read clear there while this diagnostic reports it. Rounding to the 1e-8 grid can move an area that is within rounding error of the threshold to either side of it, in either direction relative to the kernel. Floating-point coordinates still have finite resolution.

Desktop lifecycle and rendering

OverlapReportState and OverlapGeometryStamp in Core hold the testable request policy. The stamp compares ordered part identities, exact pose scalars, drawing and program references, cutoff status, and plate identity. It is not a geometry hash: any new editor that mutates a clean program in place must call PlateView.InvalidateOverlapCheck() before loading/mutation. Current live clean program editing goes through EditNestForm.EditDrawingsInConverter_Click; metadata-only edits do not change material. In-place hole-program edits require the same explicit invalidation.

OverlapOverlayController owns UI-thread captures, background analysis, request generations, cancellation, and the GDI display cache. EditNestForm enables its automatic recheck with PlateView.SetOverlapAutoCheck(() => Nest.Units); other PlateView hosts (fill previews, pattern tiles) stay manual. The debounce decision is the Linux-testable OverlapAutoCheckScheduler: collection events and every paint's stamp comparison restart a WinForms timer, and the tick starts a check only if the stamp is unchanged since the last observation and no interaction is active.

The controller passes one OverlapMaterialCache to PlateOverlapAnalyzer.Capture(parts, cache) and its last published report to Analyze(snapshot, previous). The cache keeps each clean Program's converted entities and prepared, validated material (weakly keyed by program reference; a changed code count or rotation is detected). Preparing material dominates first-check time for drawings with many holes. Incremental analysis reuses a pair only when both parts have the same cached source, bit-identical pose, and the same relative input order (clipping is operand-order sensitive), then renumbers it. InvalidateOverlapCheck() clears the cache, baseline and every highlight, so in-place program editors must keep calling it before loading.

Moving one part hides only highlights involving changed parts. Unchanged pairs remain visible throughout the quiet period and background recheck, sharing their existing immutable regions rather than recalculating them. OverlapReportState keeps these DisplayPairs separate from its full Report: the full report is unavailable and the label stays pending/out-of-date/checking until a fresh result is published. Retained highlights are known overlaps, never an all-clear for the edited layout. Each paint checks exact poses and references again, including further edits while an earlier check is pending. Hover details remain disabled until the full report is current. Collection edits conservatively discard pairs whose ordered input slots changed; this display-only path does not renumber them. Explicit geometry invalidation, plate switch, handle loss, cancellation and failure clear all retained highlights.

Measured on 389 real PEP-converted plates (252 nests), a from-scratch check takes median 0.8 ms, p99 97 ms and max 3.2 s. Nearly all of the slow cases are first-time material preparation for a hole-heavy drawing. With material prepared, clipping every candidate pair and placing markers takes median 0.05 ms, p99 34 ms and max 76 ms (markers added about 0.4 ms per overlapping pair). The triangle-pair kernel took up to 2.6 s on the same plates. On those plates Clipper2 and the previous kernel found identical pair, clamp and issue sets. Areas differed by at most 0.0002 square units, always smaller from the kernel, consistent with its dropping fragments below its area threshold. With the previous kernel, an incremental recheck after moving one part took median 0.1 ms, p99 20 ms and max 35 ms. A comparison against uncached full analysis over 2505 edits (nudge, drag onto another part, move three, delete first, swap order) matched exactly. It checks freshness before publication and painting. Handle destruction/disposal cancels work and releases paths; old completions cannot replace a newer report. Snapshot conversion and clipping never run in paint or mouse-move handlers.

PlateView draws the controller overlay after work-area/debug-remnant drawing and before action paint subscribers and hover tooltips. Island outlines and reversed holes go into one consistently wound path that is filled once, so holes stay empty and triple coverage does not darken. World-to-graph conversion excludes pan, because PlateView already applies origin translation. Paths are rebuilt for displayed-pair/scale changes, not ordinary repaints or panning. The state label saves/restores graphics state. Marker hit tests use only cached report coordinates and DPI-scaled screen radii. Hover clears on edits, mode/request/view changes, leave, and teardown. Diagnostic details draw above action adorners and take precedence over the normal part-name tooltip only while visible.

Next hardening: the first check of a plate with a hole-heavy drawing can still take seconds, and cancellation cannot interrupt the interior of material preparation or one Clipper2 intersection.

Verification

OpenNest.Tests/Diagnostics/PlateOverlapAnalyzerTests.cs exercises analytical rectangle regions/areas, containment and contact, both operands' holes, concave and disconnected intersections, connected islands with holes (including an island enclosed by both parts' holes), curves, baseline rotation, large translations, deterministic pair ordering against an exhaustive rectangle oracle, invalid inputs, snapshot isolation, read-only output, cutting-program independence, and cancellation. Run:

dotnet test OpenNest.Tests/OpenNest.Tests.csproj --filter 'FullyQualifiedName~PlateOverlapAnalyzerTests|FullyQualifiedName~OverlapReportStateTests|FullyQualifiedName~PolygonAreaMomentsTests|FullyQualifiedName~OverlapPairPresentationTests|FullyQualifiedName~OverlapHoverPagesTests|FullyQualifiedName~IncrementalOverlapAnalysisTests|FullyQualifiedName~OverlapAutoCheckSchedulerTests|FullyQualifiedName~OverlapMarkerTests|FullyQualifiedName~PolyLabel'

IncrementalOverlapAnalysisTests compares incremental rechecks with uncached full analysis across moves, rotation, deletion, insertion, order swaps, renames and coincident duplicates, and covers pair reuse, issue renumbering, cache clearing and cancellation. OverlapAutoCheckSchedulerTests covers the quiet period, interaction waits, and the no-retry rule for canceled or failed layouts. OverlapReportStateTests verifies request supersession, exact pose/reference freshness, per-pair display retention through repeated edits and pending checks, hard invalidation, cancellation, and incomplete-versus-clear messaging. PolygonAreaMomentsTests covers analytic centers, unequal/disconnected fragments, hole subtraction, winding, closure, large translations, and invalid/overflow cases. OverlapPairPresentationTests checks adaptive unit formatting, sequence labels, coincident ordering, and zoom-independent DPI hit radii. OverlapHoverPagesTests proves bounded continuation pages retain every pair and long/Unicode name, with navigation bounds and explicit tiny-view failure. OverlapMarkerTests covers the pole, the scan-line fallback after an exhausted search budget, and the last-resort fallback; PolyLabelDifferentialTests proves the heap queue returns bit-identical poles to the former sorted list, so label positions elsewhere do not move. OpenNest.WinForms.Tests/PlateOverlapOverlayTests.cs adds STA worker/publication, menu/MDI, path-cache, uniform-fill pixel, control-lifetime, and automatic-recheck (debounce, drag detection, busy wait, supersession, display/status) checks. Run those on Windows:

dotnet test OpenNest.WinForms.Tests/OpenNest.WinForms.Tests.csproj

Linux can cross-build with -p:EnableWindowsTargeting=true, but that does not execute Windows tests or verify appearance, DPI, or interaction. On Windows, check partial overlap, containment, inside-hole placement, markers on concave, holed and two-patch overlaps, pan/zoom and quadrant alignment, changed-pair clearing and unchanged-pair retention during edits and pending rechecks, full clearing on plate switches and converter cancellation, the pending label and automatic recheck after dragging a part onto another, crowded-marker PageUp/PageDown access to the last pair, and repeated check/toggle/close cycles without GDI/disposed-control errors.