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02cc9dab57 Boundary surface preparation (weld, manifold/orientation, exact self-intersection, feature edges) and mesh.surface.check (#15)
* mesh: boundary surface preparation (weld, manifold and orientation checks, exact self-intersection, feature edges)

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01NmAttHhUZTokgPeEJia8sm

* engine: mesh.surface.check on an open design's body or an imported surface

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01NmAttHhUZTokgPeEJia8sm

* engine: struct-init the test session

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01NmAttHhUZTokgPeEJia8sm

* surface: weld at an absolute distance too; the engine welds CAD tessellations at twice SolidCraft's linear tolerance

Faces of a SolidCraft tessellation carry their own copies of shared boundary points, which agree
only to within the kernel's tolerance (up to ~2e-6 mm on the test corpus).

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01NmAttHhUZTokgPeEJia8sm

* docs: surface preparation in the literature survey, architecture and roadmap

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01NmAttHhUZTokgPeEJia8sm

* surface: simplify after review

- The weld distance travels with the mesh (SurfaceMesh::weld_distance, set by Shape::tessellate),
  so every consumer welds a tessellation correctly without opting in.
- Exact tests are infallible on predicates::orient2d_projected (shared with generic_orient2d), and
  compute each vertex's plane side once per pair with an early reject.
- One Box3 for the weld, the BVH and shells; a Half struct for edges; the weld's two lookups share
  one loop, with chained grid cells; cached normals for feature edges; shared parameter helpers.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01NmAttHhUZTokgPeEJia8sm

* corpus: boundary surface preparation as a corpus stage

20 of 21 parts are valid boundaries with their expected genus; cross-cylinders' tessellation has
cracks and flipped triangles where its two intersection curves meet.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01NmAttHhUZTokgPeEJia8sm

---------

Co-authored-by: jyviko <2501648+jyviko@users.noreply.github.com>
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
2026-10-13 16:01:42 -04:00

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Roadmap

ModelCraft's goal is CAE modeling on par with Abaqus/CAE, Nastran pre-processors and LS-PrePost, with hexahedral meshing as the centre of gravity, plus its own linear solver. Abaqus/CAE is the reference for scope (its documentation is excellent and its solver strong); its application is where we aim to be clearly better: parametric geometry from SolidCraft, sets that survive remeshing, automatic hex partitioning, undo, a text-diffable model and agent control. The capability checklist is docs/parity.md.

Order (revised 2026-10-13): one end-to-end slice first — SolidCraft part → named faces → sets → mesh → material and section → BCs and loads → static and frequency steps → Abaqus, Nastran and LS-DYNA decks and our own solve → contour plot — on tet meshes, so every hex mesher lands in a pipeline that already produces solvable, verified models. Then hex: structured (sweep and mapped, with partitions proposed automatically) before octree all-hex, because that is how analysts get hex meshes today and it gives the best elements where stresses are read.

Milestone Scope Status
M0 Foundation Workspace, quality gates, FE model, command engine with rollback and panic guard, CLI, geometry boundary on SolidCraft done
M1 Geometry in and surface preparation Open .solidcraft designs with persistent face names, assemblies placed (done); face-tagged 3MF (done); test corpus, cargo xtask corpus (done); exact predicates (done); quality metrics and certified validity gate (done); weld, closed/manifold/orientation and self-intersection checks, feature edges (modelcraft-mesh::surface, mesh.surface.check, done) in progress
M2 Tet meshing and size field Size field (global, per face and edge seeds, curvature and proximity); Bowyer–Watson Delaunay (exact, symbolic perturbation, verified; modelcraft-mesh::delaunay, done); robust CDT boundary recovery (Diazzi et al. 2023); Delaunay refinement, ODT smoothing, sliver removal; tet4 and tet10 with mid-side nodes on the B-rep; mesh verify per set in progress
M3 First deck Sets and surfaces bound to SolidCraft face, edge, vertex and body names, resolved after meshing; materials (isotropic and orthotropic elastic, density) with a unit-system label and consistency check; sections (solid, shell, beam profiles) assigned by set; element formulation per region mapped to each solver; BCs (fixed, displacement, symmetry); loads (force and moment on reference points, pressure, gravity); reference points with kinematic and distributing coupling; steps (linear static, frequency) with explicit per-step load and BC tables and output presets; writers for Abaqus input, Nastran SOL 101/103 and LS-DYNA implicit; the .modelcraft file planned
M4 Own solver and first results Linear static and modal solver (tet4/10, hex8, hex20; sparse direct, Lanczos), verified against analytic solutions; deformed shape, contours, mode shapes, probes, reaction sums planned
M5 Structured hex 2D quad meshing of faces; mapped hex of six-sided regions; sweep meshing; conforming interfaces and tet–hex transition; automatic decomposition into sweepable and mappable regions, proposed as SolidCraft splits planned
M6 Automatic hex Octree/grid-dual all-hex for any part; hex-dominant by tet recombination; polycube for blocky parts; smoothing, untangling, boundary padding, layers through thin walls; mesh editing and orphan-mesh import planned
M7 Assemblies and contact Part instances from SolidCraft occurrences; tie between non-matching meshes; general and pairwise contact with automatic pair detection, friction; bolt pretension, springs, point masses; amplitudes, multiple steps; nonlinear static steps in decks planned
M8 Materials, explicit, shells, composites Plasticity, hyperelasticity, damage data per solver; explicit dynamics decks (Abaqus/Explicit, LS-DYNA); midsurface shells; composite layups and material orientations, continuum shells on swept hex; heat transfer planned
M9 Post-processing and deck readers Results readers for public formats (Nastran OP2, LS-DYNA d3plot, Abaqus .fil); XY and path plots, cuts, display groups, free-body forces; deck readers that keep unknown keywords; mesh convergence studies planned
Continuous: desktop and agents Desktop app (viewport, model tree, commands, control channel: done), MCP server, browser build, command schema as the public API started