Unified cutting planner: direct-XY proposals

OpenNest.Engine.CuttingPlanning.CuttingPlanService plans contiguous whole-part programs. It can retain fixed programs or jointly choose internal contour order, entries and whole-part order using explicitly confirmed cutting parameters. It returns an owned proposal, not an Apply transaction or a replacement desktop command. Existing desktop sequencing, assignment and posting review are unchanged.

Capture before worker planning

Create a CuttingPlanRequest, then call Capture while source placements, programs and settings are stable. Pass that snapshot to Plan on a worker; Plan(request) combines these steps synchronously. The modeled starting point defaults to Vector.Zero, not a discovered controller position.

var request = new CuttingPlanRequest(parts, startPoint: start,
    confirmedParameters: parameters, expansionBudget: 20000,
    maxEntries: 16, preservePartOrder: false);
var snapshot = CuttingPlanService.Capture(request, cancellationToken);
var result = CuttingPlanService.Plan(snapshot, cancellationToken);

Omitting confirmedParameters preserves the original fixed-program contract: locked and unlocked programs stay fixed; only whole-part order may change.
Supplying confirmed parameters enables regeneration for unlocked placements. eligibleParts can restrict it to an explicit reference-based subset; an empty subset retains all programs but still checks their leads against owned material. Locked placements never regenerate. Foreign or duplicate eligible identities are invalid; eligibility without confirmed parameters is invalid.
preservePartOrder fixes whole-part order, not eligible internal contour choices.
Parameters are caller-confirmed inputs. The service does not recover missing operator settings or silently change lead styles to find a solution.

Capture owns clean geometry, placed programs and required settings. Source Part references are identity handles only: workers never read their mutable state. Clean geometry accounts for the base program's existing rotation before applying placement rotation; placement translation is applied once. Subprogram copying must not rotate shared programs through their property setters. No live drawings are attached to preview plates, so capture/search do not change quantity accounting. The snapshot is historical, not a freshness check against later edits.

Search and exact output

With regeneration, the bounded deterministic search considers whole-part order, internal contour order and native entry candidates together. Internal contours precede their own perimeter; parts remain contiguous. Backtracking can revisit an earlier entry when a later part cannot be reached safely.

Candidates use native closest points, vertices, midpoints and circle angles in stable order, capped by maxEntries. Circle rounding, clamping, corner resolution and tab trimming happen during emission. Validation uses the actual emitted motions, never the nominal entry point alone. Existing lead styles are not shortened, disabled or substituted as a search fallback.

Every candidate rapid is checked against contours already completed, including earlier holes in the same part. Future contours are not yet obstacles. Actual lead-in and lead-out line/arc paths must stay in target scrap and avoid other placed material; holes in other parts remain scrap. Tangent/coincident contacts outside the genuine target contour joint and numerically uncertain queries refuse. Material capture supports a simple closed perimeter minus disjoint, non-nested holes; unsupported topology is not a bounding-box approximation.

Candidates rank by actual modeled rapid distance with stable source/contour/entry ordinals. Hash values and drawing names are not tie breakers. The expansion budget counts rejected candidates and frontier ranking as well as accepted moves, before emission; it is not a wall-clock timeout. Callers can cancel. Exhaustion may occur before already-generated siblings are traversed; it returns a refusal, not an unranked fallback or a proof of geometric impossibility.

Selected programs are replayed from the beginning with a fresh checker and fresh lead validation, without regenerating them or trusting cached search verdicts. Arrival positions use actual departures, including lead-outs and subprograms. ProposedOrder retains source identities/poses; CopyProgram() returns an independent deep copy of each exact captured/generated program. ContourChoices are nominal choice metadata, not a substitute for reading actual execution. Neither obtaining a proposal nor copying its programs installs them on live parts.

Results and refusal

Ready and IndependentlyReplayed describe the modeled proposal only. In the no-parameter fixed route, replay checks rapid crossings, missing leads and incomplete retention; it does not add regeneration-mode material/lead checks. In regeneration mode, replay also checks actual lead paths and contour accounting against owned clean material. Neither mode certifies final NC, production cutting readiness or physical machine safety.

Findings and source ordinals use the original zero-based source list, not proposed sequence positions. A non-ready result contains no proposed order or unsafe fallback.

ConstraintConflict: fixed programs or explored fixed routing violate the modeled constraints. Locked internal crossings cannot be repaired by regeneration.
UnsupportedGeometry: unsupported motion/material semantics or an incomplete check. Open nominal outlines, ambiguous release states, cutoff dependencies and scribe-only source drawings are not silently accepted.
InvalidInput: malformed/missing/duplicate placements or settings, invalid geometry, empty input, invalid eligibility or nonpositive bounds.
NoSolutionWithinBudget: the bounded/capped search found no complete proposal; it does not prove no possible geometric route exists.
Cancelled: capture, search or replay cancelled without live mutation.

Malformed original executed graphs are refused, not salvaged. Valid but incomplete old programs can regenerate from clean geometry. Genuine tab gaps are retained; stale tab settings do not establish retention. A lead-out that may bridge a tab or an invalid emitted tabbed arc is refused, not automatically repaired.

Remaining integration boundaries

The service does not establish clean-material non-overlap, inner-part-before-host release dependencies, cutoff order or physical retention strength. It does not install programs atomically, check freshness at Apply, write CNC, or set posting consent. A Ready proposal can still be unsuitable for cutting.

Later slices add containment/cutoff dependencies and exact freshness/atomic Apply, then desktop integration and legacy automatic-path retirement. Windows interaction, supplied-job coverage and actual posted order remain separate acceptance gates. Fresh pre-post verification is still required; it is not a physical safety qualification.

Portable regression gate

dotnet test OpenNest.Tests/OpenNest.Tests.csproj -c Release --filter 'FullyQualifiedName~CuttingPlanning|FullyQualifiedName~PostVerificationAnalyzerTests'

Synthetic fixtures exercise whole-part routing and internal-hole crossing repair, locked/ineligible refusal, actual native lead paths, shared subprograms, ownership, entry/whole-part backtracking, deterministic budgets, cancellation and fresh replay rejection. Retained emission characterizations cover styles, winding, corner rules, circle rounding/clamping and tabs; unsupported cases remain explicit refusals.

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