Patch fills non-planar edge loops with one smooth face (#250) (#472)

* Add a one-surface fill of closed 3D loops to geom

A closed loop of curves that does not lie in a plane has no exact surface;
the usual answer is one smooth face fitted over it. fill_loop does that:

- the loop's best-fit plane (Newell normal), with a frame chosen from the
  loop itself so the result does not depend on where the loop starts, its
  direction, or where the part sits
- the loop seen along that normal must be simple and must not fold or run
  along the normal; otherwise it is refused ("not supported yet"), never
  filled with wrong geometry
- one non-rational bicubic B-spline height field over the loop's box,
  fitted by least squares to the loop's samples (The NURBS Book 9.4.1,
  9.4.3, eq. 9.62/9.65) with a thin-plate smoothness term
  lambda*A*int(h_uu^2 + 2 h_uv^2 + h_vv^2), A one grid cell's area, so the
  fit is the same at any scale; only planes are reproduced exactly
- span counts per direction (long narrow loops fit), refined until the
  loop is within tolerance, else refused with the deviation reached

bspline: bisected span search, basis functions on a stack array, one
clamping helper shared by curves and surfaces, one binomial helper.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01J53sR6gEaVt56soFDpTck8

* Patch fills non-planar loops of edges with one smooth face (#250)

surface.patch with edges refused any loop that is not planar ("not
supported yet: patching a loop that is not planar"). It now fills it:

- planar loops still get one exact planar face, but planarity is certified
  conservatively: lines by their ends, B-spline/NURBS edges by their control
  points, intersection curves by their samples lying on a support plane
  within tolerance; a loop that can't be certified is filled instead
- other loops get one face from geom's fill_loop, bounded by the body's own
  chained edges, whole (no split): its history is one generated face whose
  edges are the body's, and it stitches back into a closed solid
- intersection-curve edges are sampled by a seeded, guarded double
  projection shared by the planarity test and the fill (plane_fit)
- the face tolerance is 10x the planarity tolerance (documented: later
  operations take the face to contain its edges within it)
- edge picking runs inside the guard; the geom->truck conversion is shared
  with the T-spline sheets (spline_conv); the Newell plane fit is shared with
  STEP import

Tests: 3- to 8-sided, concave (dart, arrow, plus), flat-corner, two-edge and
imported rims fill as one face and stitch closed (volumes against an
independent integral); finite mesh normals, same result for any pick order
or placement; non-height-field loops and too-fine detail are refused.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01J53sR6gEaVt56soFDpTck8

* Test the Patch dialog filling a non-planar loop of picked edges

The Patch dialog's only test used a sketch profile. Picking the four
curved rim edges of a box cut by a sideways cylinder now makes one
surface.patch command whose result is a single smooth face over the rim.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01J53sR6gEaVt56soFDpTck8

---------

Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
This commit is contained in:
Irakli KourtisandClaude Opus 5.5 authored and GitHub committed 2026-10-12 21:37:01 -04:00
1 parent af0440aaab
commit 201e9d5f9f
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+1648 -146

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@@ -13,7 +13,7 @@ pub static COMMANDS: &[CommandSpec] = &[
CommandSpec::new("surface.patch", "Patch", patch)
.at("SURFACE", "CREATE")
.icon("patch")
.params("sketch?: id|name and profiles? (planar patches of sketch regions) | edges: [[x,y,z]] (points on a closed loop of a body's edges) and body?; name?, body_name?"),
.params("sketch?: id|name and profiles? (planar patches of sketch regions) | edges: [[x,y,z]] (points on a closed loop of a body's edges: one face on them, planar when the loop is, else a smooth B-spline surface) and body?; name?, body_name?"),
CommandSpec::new("surface.stitch", "Stitch", stitch)
.at("SURFACE", "MODIFY")
.icon("stitch")
@@ -129,7 +129,8 @@ mod tests {
solidcraft_kernel::measure(&st.body(name).unwrap().body).unwrap().volume
}
/// A rectangle patched, trimmed by a plane and thickened; a box's faces stitched back.
/// A rectangle patched, trimmed by a plane and thickened; a box's open top patched; a rim
/// that is not planar patched.
#[test]
fn patch_trim_thicken_and_stitch() {
let mut s = Session::default();
@@ -148,6 +149,24 @@ mod tests {
run(&mut s, "solid.box", json!({"length": 10, "width": 10, "height": 10, "corner": [20, 0, 0], "body_name": "Cup"}));
run(&mut s, "surface.patch", json!({"edges": [[25, 0, 10], [30, 5, 10], [25, 10, 10], [20, 5, 10]], "body": "Cup", "body_name": "Lid"}));
assert!(s.world_state().body("Lid").unwrap().body.is_surface());
// A rim that is not planar: a box with its top cut away by a sideways cylinder.
run(&mut s, "solid.box", json!({"length": 28, "width": 28, "height": 20, "corner": [-14, -14, 0], "body_name": "Saddle"}));
run(
&mut s,
"solid.cylinder",
json!({"radius": 40, "height": 120, "base": [0, -60, 50], "axis": "Y", "operation": "cut", "targets": ["Saddle"]}),
);
let z = |x: f64| 50.0 - (1600.0 - x * x).sqrt();
let rim = json!([[14, 0, z(14.0)], [0, 14, z(0.0)], [-14, 0, z(-14.0)], [0, -14, z(0.0)]]);
run(&mut s, "surface.patch", json!({"edges": rim, "body": "Saddle", "body_name": "Cover"}));
let st = s.world_state();
let cover = &st.body("Cover").unwrap().body;
assert!(cover.is_surface() && cover.face_count() == 1);
// The cover is a smooth surface on the rim, close to the cylinder that cut it (its area
// within 1% of the cylinder's inside the rim).
let area = solidcraft_kernel::measure(cover).unwrap().area;
let want = 28.0 * 40.0 * 2.0 * (14.0f64 / 40.0).asin();
assert!((area - want).abs() < want * 1e-2, "{area} vs {want}");
assert!(s.execute("surface.thicken", &json!({"bodies": ["Nope"], "thickness": 1})).is_err());
assert!(s.execute("surface.trim", &json!({"body": "Sheet"})).is_err());
}