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Record release-build boolean timings and a recommendation
Times brep::combine in release against the pinned cadkernel: about 1-2 s for curved operands, 1-2 ms for planar, versus 23 s in debug. Records the kernel's frequent refusals, the host-thread and 30 s script-budget implications, and recommends a synchronous Boolean operation that surfaces refusals. Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
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@@ -109,10 +109,10 @@ is refused with a clear message instead of being rewritten.
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## Risks and open questions
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1. **Boolean speed.** About 23 s each in a debug build. Time them in release
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before deciding whether they can run on the host thread (the GUI BOOLEAN
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command has the same cost) or need a background task. Everything else is
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instant.
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1. **Boolean speed.** Measured in release, see "Boolean timings" below: about
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1 to 2.2 s for a box and a cylinder, 0.2 s for two spheres and 1 to 2 ms for
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planar-only operands, against 23 s in a debug build. The kernel also refuses
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many curved cases, which matters more than speed.
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2. **Interoperability cannot be verified here.** `solid_to_sat` is verified by
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OCS's own lifter. Whether AutoCAD accepts the SAT/SAB that OCS writes is not
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testable without AutoCAD, so completion should be scoped as "OCS round trip",
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@@ -137,3 +137,62 @@ is refused with a clear message instead of being rewritten.
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Phase 1 alone would move Solid3D from blocked to complete-in-OCS.
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**Status (2026-09-20): phase 1 is done.** `HostApi::solid_operation` (create primitive and rigid transform), the `doc.solids` Python API and `audit_python_solid3d_lifecycle_over_real_ipc` are in; Solid3D is complete, Body moves through the same channel. Design B was implemented as recommended. Region creation from a closed profile followed (`RegionFromProfile`). Plane surfaces and extrusions (`SurfaceFromProfile`, `Extrude`) followed. Only booleans remain, plus lofted, revolved, swept and NURBS surfaces.
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## Boolean timings (release build)
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Measured 2026-09-20 in a scratch crate built with `--release` (opt-level 3)
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against the same cadkernel revision OCS pins (`6f046af`, features `acis` and
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`offset`), calling exactly what OCS's `solid_model::boolean_result` calls:
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`brep::operation_tolerance` then `brep::combine`. A debug build of OCS is about
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22 times slower, so booleans must never be exercised in a debug test run. The
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scratch program is not in the repository; to repeat it, depend on cadkernel at
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that revision and time `brep::combine` on `brep::make::{cuboid, cylinder,
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sphere, torus}` operands.
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| Operation | Time | Result |
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|---|---|---|
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| box union / subtract / intersect cylinder (10x6x4 box, r=2 cylinder) | 1.05 to 1.08 s each, identical on repeat runs | ok |
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| same, operands scaled 10x and 100x | 2.21 s and 2.21 s | ok |
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| box union / subtract box (planar only) | 0.001 to 0.002 s | ok |
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| sphere union sphere (overlapping) | 0.22 s | ok |
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| sphere subtract sphere (overlapping) | 0.23 s | refused `CutRefused` |
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| box subtract sphere (sphere cutting the box faces) | 1.28 s | refused `Coincident` |
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| sphere union torus (disjoint) | under 1 ms | refused `NoClosedForm` |
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| torus subtract cylinder through the ring | under 1 ms | refused `NoClosedForm` |
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| drill a first cylinder hole in a box | 0.03 s | ok |
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| drill a second hole in the drilled box | under 1 ms | refused `CutRefused` |
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What this means:
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- **Speed is acceptable.** A curved boolean costs 0.2 to 2.2 s, the same cost as
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the GUI BOOLEAN command, and planar work is instant. The 23 s seen earlier was
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a debug-build artifact.
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- **It blocks the host thread.** The plugin's `PY_RUN` is a synchronous dispatch
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and nested host requests run inline, so a script freezes the UI while a
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boolean runs. One to two seconds per operation is tolerable; a script with
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dozens is not.
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- **The whole script has a budget.** A `Dispatch` call uses the 30 s default
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timeout (`OCS_PLUGIN_CALL_TIMEOUT_SECS`, with a 10 s floor), and nested host
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work counts against one deadline. Roughly fifteen curved booleans in a single
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script would exceed it.
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- **Refusals are the real limit.** The kernel says no often: coincident faces, a
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cut it has no closed form for, torus operands, and, surprisingly, a second
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cut in a body that was already drilled. Refusals are fast and leave the inputs
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intact, which is the behavior the API already relies on, but it means booleans
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will be a partial feature that fails with a reason, not a general one.
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- **Timing is not proportional to size.** Scaling the operands 10x doubled the
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time, 100x changed nothing more, so the cost is dominated by the surface
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intersection setup rather than the geometry size.
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### Recommendation
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Add `SolidOperation::Boolean { first, second, operation, layer }` and run it
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synchronously on the host thread, surfacing the kernel's refusal (`Coincident`,
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`CutRefused`, `NoClosedForm`, ...) verbatim in the error and leaving both
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operands untouched on failure. Build the result with the existing
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`entity_with_boolean_body` path so it inherits the lossless verification.
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Test it with **planar** operands (millisecond cost, safe in debug) plus one
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`#[ignore]` curved case that documents the release-only runtime. Document the
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30 s script budget and that chained cuts on a drilled body are often refused.
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Do not move booleans to a background thread yet: it would need cancellation and
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undo coordination for a cost that is one to two seconds.
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