engine: geometry.defeature takes features out of the design for meshing (#433)

Suppresses the SolidCraft features named (holes filled, fillets and chamfers back to
their sharp edges, bosses removed) and rebuilds the design; a feature that cannot be
suppressed alone is merged into its neighbour for meshing only. Kept in the model,
replayed on open, undoable; geometry.defeature.delete turns them back on.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01UhhZMBTviDQxZvwnyP89fo

crates/engine/src/catalogue.rs

@@ -317,6 +317,14 @@ pub static CATALOGUE: &[Capability] = &[
         "Split a face along a datum plane for meshing only: two faces on its surface, the cut an edge between them",
         &["geometry.face.split.delete"],
     ),
+    covering(
+        "geometry.defeature",
+        "Defeature",
+        Geometry,
+        "Prepare",
+        "Take small holes, fillets, chamfers and bosses out for meshing: the design rebuilt without their features",
+        &["geometry.defeature.delete"],
+    ),
     covering(
         "geometry.stitch",
         "Stitch",

crates/engine/src/cmd/datum.rs

@@ -470,14 +470,19 @@ fn cuts(model: &Model) -> Vec<Cut> {
         .collect()
 }
 
-/// `design` cut by `model`'s partitions, then with its face merges and its face splits (those
-/// along a suppressed datum left out; the design as opened when the model has none).
+/// `design` without the features `model` defeatures, cut by its partitions, then with its face
+/// merges (after those of the features defeatured virtually) and its face splits (those along a
+/// suppressed datum left out; the design as opened when the model has none).
 pub(crate) fn partitioned(design: &Design, model: &Model) -> Result<Design> {
-    let merges: Vec<Merge> = model
-        .face_merges()
-        .iter()
-        .map(|m| Merge { name: m.name.clone(), body: m.body.clone(), faces: m.faces.clone(), into: m.into.clone() })
-        .collect();
+    let defeatures: Vec<fieldcraft_geometry::defeature::Defeature> =
+        model.defeatures().iter().map(|d| fieldcraft_geometry::defeature::Defeature { name: d.name.clone(), features: d.features.clone() }).collect();
+    let (design, mut merges) = design.defeatured(&defeatures)?;
+    merges.extend(model.face_merges().iter().map(|m| Merge {
+        name: m.name.clone(),
+        body: m.body.clone(),
+        faces: m.faces.clone(),
+        into: m.into.clone(),
+    }));
     let splits: Vec<fieldcraft_geometry::face_split::FaceSplit> = model
         .face_splits()
         .iter()

crates/engine/src/cmd/defeature.rs

@@ -0,0 +1,228 @@
+//! Defeaturing for meshing: `geometry.defeature` takes holes, fillets, chamfers and small bosses
+//! out of the open design by suppressing their SolidCraft features (virtually, as a face merge,
+//! when a feature cannot be suppressed on its own).
+//!
+//! A defeature is part of the model (`fieldcraft_model::Defeature`, by feature id); the geometry
+//! layer applies it to the design as opened (`fieldcraft_geometry::defeature`), before the
+//! partitions, whenever the design is opened or cut again ([`super::datum::partitioned`]), so the
+//! meshers, the viewport and the checks all see the part without them.
+
+use std::collections::BTreeSet;
+
+use fieldcraft_model::Defeature;
+use serde::Deserialize;
+use serde_json::{Value, json};
+
+use crate::requirement::Requirement;
+use crate::{CommandKind, CommandSpec, EngineError, Result, Session};
+
+pub const DEFEATURE: CommandSpec = CommandSpec {
+    id: "geometry.defeature",
+    label: "Defeature",
+    params: r#"{"name": "Small", "features": [3, "F7"] (feature ids, as geometry.features lists them; or the text "3, F7")} — takes features of the open design out for meshing: the design is rebuilt without them, as SolidCraft builds it with them suppressed (a hole filled, a fillet or chamfer back to its sharp edge, a boss gone), and the other faces keep their persistent names. A feature that cannot be suppressed alone (a later feature needs it, or a body would go) is defeatured virtually instead: its faces are merged into the neighbour they share the longest edges with, for meshing only (virtual topology; the B-rep keeps it). A feature that builds a body or a sketch, or one the design lacks, is an error. Kept in the model by feature id and applied again whenever the design is opened (before the partitions); the same name again replaces its features. A suppressed feature affects every body it shaped. The bodies lose their meshes (`replaced`; remesh them); sets naming their faces are `stale_sets`. Replies `suppressed` (feature ids), `virtual` ([{feature, reason}]) and `bodies`. One undo step; geometry.defeature.delete turns them back on"#,
+    form: Some(super::forms::DEFEATURE),
+    kind: CommandKind::Model,
+    requires: &[Requirement::Design],
+    run: defeature,
+};
+
+pub const DEFEATURE_DELETE: CommandSpec = CommandSpec {
+    id: "geometry.defeature.delete",
+    label: "Delete Defeature",
+    params: r#"{"name": "Small"} — turns a defeature's features back on: the design is rebuilt with them; the bodies they shaped lose their meshes (`replaced`)"#,
+    form: Some(super::forms::DEFEATURE_DELETE),
+    kind: CommandKind::Model,
+    requires: &[Requirement::Defeature],
+    run: delete,
+};
+
+/// A feature id: `3` or `"F3"`.
+#[derive(Deserialize)]
+#[serde(untagged)]
+enum FeatureId {
+    Id(u64),
+    Name(String),
+}
+
+/// The feature ids of `features`: a list, or the form's text (`3, F7`).
+fn ids(p: &Value) -> Result<Vec<u64>> {
+    let given: Vec<FeatureId> = match p.get("features") {
+        Some(Value::String(t)) if t.len() <= 64 * 1024 => {
+            t.split([',', ' ', ';']).filter(|w| !w.is_empty()).map(|w| FeatureId::Name(w.to_string())).collect()
+        }
+        _ => super::req(p, "features")?,
+    };
+    if given.is_empty() || given.len() > fieldcraft_model::virtual_faces::MAX_DEFEATURE_FEATURES {
+        return Err(EngineError::invalid("features", format!("1 to {} feature ids", fieldcraft_model::virtual_faces::MAX_DEFEATURE_FEATURES)));
+    }
+    let mut out = Vec::with_capacity(given.len());
+    for f in given {
+        let id = match f {
+            FeatureId::Id(id) => Some(id),
+            FeatureId::Name(n) => n.strip_prefix('F').unwrap_or(&n).parse().ok(),
+        };
+        match id {
+            Some(id) if !out.contains(&id) => out.push(id),
+            Some(_) => {}
+            None => return Err(EngineError::invalid("features", "feature ids: 3 or \"F3\"")),
+        }
+    }
+    Ok(out)
+}
+
+/// The bodies of the open design (as opened) that features `ids` shaped.
+fn shaped(s: &Session, ids: &BTreeSet<u64>) -> Vec<String> {
+    let Some(design) = s.design.as_deref() else { return Vec::new() };
+    let graph = design.undefeatured().features(None).unwrap_or_default();
+    let sources: Vec<String> = graph.into_iter().filter(|b| b.features.iter().any(|f| ids.contains(&f.id))).map(|b| b.body).collect();
+    // A body the partitions cut: each of its cells.
+    design.bodies.iter().map(|b| b.name.clone()).filter(|n| design.source_of(n).is_some_and(|src| sources.iter().any(|x| x == src))).collect()
+}
+
+/// What the design's defeatures did with the features of `name`, as the reply lists them.
+fn outcome(s: &Session, name: &str) -> (Vec<u64>, Vec<Value>) {
+    let report = s.design.as_deref().map(|d| d.defeat_report().to_vec()).unwrap_or_default();
+    let mine = report.into_iter().filter(|r| r.defeature == name);
+    let (mut suppressed, mut virt) = (Vec::new(), Vec::new());
+    for r in mine {
+        if r.method == "suppressed" {
+            suppressed.push(r.feature);
+        } else {
+            virt.push(json!({"feature": r.feature, "reason": r.reason}));
+        }
+    }
+    (suppressed, virt)
+}
+
+fn defeature(s: &mut Session, p: &Value) -> Result<Value> {
+    let name = super::name(p)?.to_string();
+    let features = ids(p)?;
+    let before: BTreeSet<u64> = s.model.defeatures().iter().filter(|d| d.name == name).flat_map(|d| d.features.clone()).collect();
+    s.model.set_defeature(Defeature { name: name.clone(), features: features.clone() })?;
+    let mut touched = before;
+    touched.extend(&features);
+    let bodies = shaped(s, &touched);
+    let merges: Vec<String> = features.iter().map(|id| format!("merge {name}-F{id}")).collect();
+    let mut errors = vec![format!("defeature {name}")];
+    errors.extend(merges);
+    let reply = super::virtual_faces::reapply(s, &errors, &bodies, json!({"name": name}))?;
+    let (suppressed, virt) = outcome(s, &name);
+    let bodies = shaped(s, &touched);
+    let mut reply = reply;
+    if let Some(o) = reply.as_object_mut() {
+        o.insert("suppressed".into(), json!(suppressed));
+        o.insert("virtual".into(), json!(virt));
+        o.insert("bodies".into(), json!(bodies));
+    }
+    Ok(reply)
+}
+
+fn delete(s: &mut Session, p: &Value) -> Result<Value> {
+    let name = super::name(p)?;
+    let removed = s.model.remove_defeature(name)?;
+    let bodies = shaped(s, &removed.features.iter().copied().collect());
+    let mut cleared = super::datum::recut(s)?;
+    cleared.extend(super::replace::clear(&mut s.model, bodies.iter().map(String::as_str)));
+    Ok(cleared.report_if_any(s, json!({"deleted": name, "features": removed.features, "bodies": bodies})))
+}
+
+#[cfg(test)]
+mod tests {
+    use serde_json::json;
+
+    use crate::Session;
+
+    fn faces(s: &Session) -> usize {
+        s.design.as_ref().unwrap().bodies[0].faces().len()
+    }
+
+    fn hole(s: &mut Session) -> u64 {
+        let r = s.execute("geometry.features", &json!({})).unwrap();
+        r["bodies"][0]["features"].as_array().unwrap().iter().find(|f| f["operation"] == "cut").unwrap()["id"].as_u64().unwrap()
+    }
+
+    /// The sample plate: suppressing its hole gives a block meshed
+    /// without it (tet and hex), undo and redo take it out and put it back, it is saved and
+    /// replayed on open, and deleting the defeature brings the hole back.
+    #[test]
+    fn the_plate_hole_is_suppressed_meshed_undone_saved_and_restored() {
+        let (mut s, dir) = super::super::datum::tests::plate();
+        let body = s.design.as_ref().unwrap().bodies[0].name.clone();
+        assert_eq!(faces(&s), 8);
+        let id = hole(&mut s);
+        s.execute("mesh.tet.generate", &json!({"body": body, "size": 4})).unwrap();
+        let with_hole = s.model.elements().len();
+        let r = s.execute("geometry.defeature", &json!({"name": "Holes", "features": [id]})).unwrap();
+        assert_eq!(r["suppressed"], json!([id]), "{r}");
+        assert_eq!(r["replaced"][0]["body"].as_str(), Some(body.as_str()), "{r}");
+        assert_eq!(faces(&s), 6);
+        // Meshed without it: a tet mesh fills the whole block, and the block sweeps into hexes.
+        s.execute("mesh.tet.generate", &json!({"body": body, "size": 4})).unwrap();
+        let volume = |s: &Session| s.design.as_ref().unwrap().bodies[0].measure().unwrap().volume;
+        assert!((volume(&s) - 40.0 * 30.0 * 10.0).abs() < 1e-6, "{}", volume(&s));
+        assert_ne!(s.model.elements().len(), with_hole);
+        s.execute("mesh.hex.sweep", &json!({"body": body, "size": 5})).unwrap();
+        assert!(s.model.elements().values().all(|e| e.nodes.len() == 8), "a block sweeps into hexes only");
+        // Undo the meshes and the defeature: the hole is back; redo takes it out again.
+        while !s.model.defeatures().is_empty() {
+            s.execute("edit.undo", &json!({})).unwrap();
+        }
+        assert_eq!(faces(&s), 8);
+        s.execute("edit.redo", &json!({})).unwrap();
+        assert_eq!(faces(&s), 6);
+        // Saved, and replayed on open of the model and on a re-open of the design.
+        let file = dir.join("defeatured.fieldcraft");
+        s.execute("file.save", &json!({"path": file.to_str().unwrap()})).unwrap();
+        let mut t = Session::default();
+        t.execute("file.open", &json!({"path": file.to_str().unwrap()})).unwrap();
+        assert_eq!((t.model.defeatures().len(), faces(&t)), (1, 6));
+        let design = s.sources.design.as_ref().unwrap().path().to_string();
+        s.execute("geometry.open", &json!({"path": design})).unwrap();
+        assert_eq!(faces(&s), 6);
+        // Switched back on.
+        let r = s.execute("geometry.defeature.delete", &json!({"name": "Holes"})).unwrap();
+        assert_eq!(r["features"], json!([id]), "{r}");
+        assert_eq!(faces(&s), 8);
+        std::fs::remove_dir_all(dir).ok();
+    }
+
+    /// Unknown features, body-building ones and bad ids are refused and leave the model as it was.
+    #[test]
+    fn bad_features_are_refused() {
+        let (mut s, dir) = super::super::datum::tests::plate();
+        for features in [json!([999]), json!(["Fx"]), json!([]), json!("F1, x"), json!(7)] {
+            assert!(s.execute("geometry.defeature", &json!({"name": "Bad", "features": features})).is_err(), "{features}");
+        }
+        let body = s.design.as_ref().unwrap().bodies[0].name.clone();
+        let base = s.execute("geometry.features", &json!({"body": body})).unwrap()["bodies"][0]["features"][0]["id"].as_u64().unwrap();
+        let e = s.execute("geometry.defeature", &json!({"name": "Bad", "features": [base]})).unwrap_err();
+        assert!(e.to_string().contains("builds a body"), "{e}");
+        assert!(s.model.defeatures().is_empty() && faces(&s) == 8);
+        std::fs::remove_dir_all(dir).ok();
+    }
+
+    /// The bracket's 6 mm fillet is defeatured back to a sharp corner and
+    /// meshed; its holes stay.
+    #[test]
+    fn a_bracket_is_meshed_with_its_small_fillet_defeatured() {
+        let (_dir, mut s) = super::super::datum::tests::scripted(json!([
+            {"command": "sketch.create", "params": {"plane": "XY", "name": "Profile"}},
+            {"command": "sketch.line", "params": {"points": [[0, 0], [60, 0], [60, 8], [8, 8], [8, 50], [0, 50]], "closed": true}},
+            {"command": "sketch.finish", "params": {}},
+            {"command": "solid.extrude", "params": {"distance": 40, "body_name": "Bracket"}},
+            {"command": "solid.fillet", "params": {"edges": [[8, 8, 20]], "radius": 6}},
+            {"command": "solid.hole", "params": {"position": [40, 8, 20], "diameter": 8}},
+            {"command": "solid.hole", "params": {"position": [8, 32, 20], "diameter": 8}}
+        ]));
+        let g = s.execute("geometry.features", &json!({"body": "Bracket"})).unwrap();
+        let fillet: Vec<serde_json::Value> =
+            g["bodies"][0]["features"].as_array().unwrap().iter().filter(|f| f["type"] == "fillet").map(|f| f["id"].clone()).collect();
+        assert_eq!(fillet.len(), 1);
+        let before = faces(&s);
+        let r = s.execute("geometry.defeature", &json!({"name": "Fillets", "features": fillet})).unwrap();
+        assert_eq!(r["suppressed"], json!(fillet), "{r}");
+        assert_eq!(faces(&s), before - 1);
+        let r = s.execute("mesh.tet.generate", &json!({"body": "Bracket", "size": 4})).unwrap();
+        assert!(r["elements"].as_u64().unwrap_or(0) > 0, "{r}");
+    }
+}

crates/engine/src/cmd/forms.rs

@@ -1780,6 +1780,13 @@ pub const FACE_SPLIT: &[Field] = &[
 ];
 pub const FACE_SPLIT_DELETE: &[Field] = existing!("Face split", C::FaceSplit);
 pub const FACES_MERGE_DELETE: &[Field] = existing!("Face merge", C::FaceMerge);
+pub const DEFEATURE: &[Field] = &[
+    NAME,
+    text("features", "Features")
+        .help("The feature ids to take out for meshing (3 or F3), as the feature graph (geometry.features) lists them; separate them with commas.")
+        .req(),
+];
+pub const DEFEATURE_DELETE: &[Field] = existing!("Defeature", C::Defeature);
 pub const MESH_PLAN: &[Field] = &[
     reference("body", "Body", C::Body).help("The body of the design to plan (as opened, not a partition cell).").req(),
     text("name", "Name").help("The name the plan is saved under.").hint("Plan-<body>"),

crates/engine/src/cmd/mod.rs

@@ -5,6 +5,7 @@ mod cells;
 mod contact;
 pub(crate) mod datum;
 pub(crate) mod deck;
+mod defeature;
 pub(crate) mod define;
 pub mod diagnostics;
 mod edit;
@@ -79,6 +80,8 @@ pub static ALL: &[CommandSpec] = &[
     virtual_faces::FACE_ABSORB,
     virtual_faces::FACE_SPLIT,
     virtual_faces::FACE_SPLIT_DELETE,
+    defeature::DEFEATURE,
+    defeature::DEFEATURE_DELETE,
     stitch::STITCH,
     stitch::STITCH_DELETE,
     mesh::NODE_ADD,

crates/engine/src/cmd/virtual_faces.rs

@@ -98,7 +98,7 @@ fn stale_sets(s: &Session, body: &str) -> Vec<String> {
 /// Apply the model's partitions, merges and splits to the design again, failing with the error of
 /// one of `features` (`merge <name>`, `split <name>`) when it has one; the meshes of `bodies` go
 /// (their faces changed).
-fn reapply(s: &mut Session, features: &[String], bodies: &[String], reply: Value) -> Result<Value> {
+pub(super) fn reapply(s: &mut Session, features: &[String], bodies: &[String], reply: Value) -> Result<Value> {
     let mut cleared = super::datum::recut(s)?;
     let design = s.design.as_deref().ok_or_else(|| EngineError::Params("open a design first".into()))?;
     let errors: Vec<String> =

crates/engine/src/requirement.rs

@@ -38,6 +38,8 @@ pub enum Requirement {
     Stitch,
     /// A face split.
     FaceSplit,
+    /// A defeature.
+    Defeature,
     /// An edge seed.
     Seed,
     /// A size control.
@@ -90,6 +92,7 @@ impl Requirement {
             Requirement::FaceMerge => !m.face_merges().is_empty(),
             Requirement::Stitch => !m.stitches().is_empty(),
             Requirement::FaceSplit => !m.face_splits().is_empty(),
+            Requirement::Defeature => !m.defeatures().is_empty(),
             Requirement::Seed => !m.seeds().is_empty(),
             Requirement::SizeControl => !m.size_controls().is_empty(),
             Requirement::Nodes => !m.nodes().is_empty(),
@@ -134,6 +137,7 @@ impl Requirement {
             Requirement::FaceMerge => "a face merge",
             Requirement::Stitch => "a stitch",
             Requirement::FaceSplit => "a face split",
+            Requirement::Defeature => "a defeature",
             Requirement::Seed => "an edge seed",
             Requirement::SizeControl => "a local size",
             Requirement::Nodes => "mesh nodes",
@@ -168,6 +172,7 @@ impl Requirement {
             Requirement::FaceMerge => "geometry.faces.merge",
             Requirement::Stitch => "geometry.stitch",
             Requirement::FaceSplit => "geometry.face.split",
+            Requirement::Defeature => "geometry.defeature",
             Requirement::Seed => "mesh.seed.edge",
             Requirement::SizeControl => "mesh.size.set",
             Requirement::Nodes => "mesh.node.add",
@@ -230,6 +235,7 @@ impl crate::schema::Collection {
             C::Stitch => Requirement::Stitch,
             C::FaceSplit => Requirement::FaceSplit,
             C::SizeControl => Requirement::SizeControl,
+            C::Defeature => Requirement::Defeature,
         }
     }
 }
@@ -373,6 +379,7 @@ mod tests {
             C::FaceMerge,
             C::Stitch,
             C::FaceSplit,
+            C::Defeature,
         ];
         let empty = Session::default();
         for c in all {

crates/engine/src/schema.rs

@@ -225,6 +225,8 @@ pub enum Collection {
     FaceSplit,
     /// A size control (`mesh.size.set`).
     SizeControl,
+    /// A defeature (`geometry.defeature`).
+    Defeature,
 }
 
 impl Collection {
@@ -254,6 +256,7 @@ impl Collection {
             Collection::Stitch => "stitch",
             Collection::FaceSplit => "face split",
             Collection::SizeControl => "size control",
+            Collection::Defeature => "defeature",
         }
     }
 }
@@ -287,6 +290,7 @@ impl Session {
             Collection::Stitch => Box::new(m.stitches().iter().map(|f| f.name.as_str())),
             Collection::FaceSplit => Box::new(m.face_splits().iter().map(|f| f.name.as_str())),
             Collection::SizeControl => Box::new(m.size_controls().keys().map(String::as_str)),
+            Collection::Defeature => Box::new(m.defeatures().iter().map(|f| f.name.as_str())),
         };
         names.take(MAX_NAMES).map(str::to_string).collect()
     }