feat: fillet fit option reduces a radius too large for its edges (#388)

* feat(kernel): typed TooLarge refusal and fillet_max search

Blend refusals caused only by the size (larger than the neighbouring faces,
taller than the walls, longer than the next edge, larger than a corner
radius) now return KernelError::TooLarge, displayed as before. fillet_max
finds the largest radius below a request at which the fillet of the edges
works, to three significant digits, by building candidates; it is an explicit
call (up to 16 fillets), not run on every refusal.

A corner edge that doesn't run square to the edge is now reported as such
instead of as a blend larger than the neighbouring faces.

Refs #293

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01TWc1smHYwTSVrVc8SNvS44

* feat: fillet fit option reduces a radius too large for its edges

solid.fillet takes fit: exact (the default, as before: a radius too large
for the geometry around the edges is refused) or reduce: the radius is
reduced to the largest that works for all the picked edges (kernel
fillet_max, three significant digits, every candidate built). The feature
stores the requested radius, so it refits on every evaluation; when it
reduces, the feature's warning says so and the command returns
radius_applied. Pattern copies of the fillet use the same rule. The file
format writes fit only when it is reduce.

The Fillet dialog gets a Radius Fit row (Exact / Reduce to Fit, constant
radius) and, when the preview reduced the radius, an Applied Radius line;
editing the feature keeps the choice.

One radius for all edges for now; per-edge radii and taper follow.

Refs #293

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01TWc1smHYwTSVrVc8SNvS44

---------

Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
Co-authored-by: bherbruck <brennen.herbruck@gmail.com>
This commit is contained in:
authored and GitHub committed 2026-10-12 16:21:17 -04:00
1 parent 3c94f59d43
commit c62879b00d
14 files changed
+316 -23

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@@ -356,7 +356,7 @@ fn build(
}
let p = joint_point(i).ok_or_else(|| unsupported("degenerate loop joint"))?;
if !crate::blend::extension_fits(f, p, *q, size * 1e-7) {
return Err(unsupported("the blend is larger than the neighbouring faces"));
return Err(crate::blend::too_large("the blend is larger than the neighbouring faces"));
}
}
// The offset arcs must not turn inside out; an arc of exactly the blend's radius shrinks
@@ -371,12 +371,12 @@ fn build(
*x = true;
}
} else if toward && a.dist(c) <= r + tol {
return Err(unsupported("the blend is larger than a corner radius"));
return Err(crate::blend::too_large("the blend is larger than a corner radius"));
}
}
}
if collapsed.iter().all(|x| *x) {
return Err(unsupported("the blend is larger than a corner radius"));
return Err(crate::blend::too_large("the blend is larger than a corner radius"));
}
let mut va: Vec<mt::Vertex> = pa.iter().map(|p| builder::vertex(p3(*p))).collect();
// A collapsed piece starts and ends at one vertex.
@@ -546,7 +546,11 @@ fn build(
let along = (from_p3(other.point()) - from_p3(v.point())).dot(target - from_p3(v.point()));
let reach = (target - from_p3(v.point())).len2();
if along <= reach + tol {
return Err(unsupported(if face_side { "the blend is longer than the next edge" } else { "the blend is taller than the walls" }));
return Err(crate::blend::too_large(if face_side {
"the blend is longer than the next edge"
} else {
"the blend is taller than the walls"
}));
}
let nb = if face_side { va.get(i) } else { vb.get(i) }.ok_or_else(|| KernelError::Failed("joint".into()))?;
let slot = seam_ends.entry(e.id()).or_insert_with(|| (e.absolute_clone(), None, None));
@@ -562,7 +566,7 @@ fn build(
let a = a.unwrap_or_else(|| e.absolute_front().clone());
let b = b.unwrap_or_else(|| e.absolute_back().clone());
if from_p3(a.point()).dist(from_p3(b.point())) < tol * 10.0 {
return Err(unsupported("the blend is longer than the next edge"));
return Err(crate::blend::too_large("the blend is longer than the next edge"));
}
seam_subst.insert(id, builder::line(&a, &b));
}