Robustness runs and the kernel fixes they found

- solvecraft-cli fuzz / fuzz-one: seeded random modelling sessions (boxes, extruded profiles with arcs, revolves; joins and cuts of boxes, cylinders and spheres, fillets, chamfers, shells, holes, patterns) on a grid that makes coincident faces and tangencies common, every step checked (command ok, every body a sound solid via the new Body::validity, volume moving the right way), plus the boolean volume identity on random primitives; one process per seed with a time limit; failures minimised to scripts
- shell/offset: corners where a curved face meets another at an angle are refined onto the moved surfaces (Newton); edges that are neither lines nor arcs are rebuilt through their moved points; one shell per piece; faces that would cross say so (not supported yet) instead of leaving a cavity inside out; flat revolved faces count as planes; the unhealed body is tried when the healed one fails
- cylinders start their seams at an odd angle (grid-aligned seams broke booleans along them)
- partial revolves of profiles touching the axis build no zero-area face on the axis
- booleans on bodies in several pieces retry a piece at a time
- regression tests for each, and a fixed set of seeds in cargo test

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01AS5Tn3xieewUSg3uxrMVdL
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bherbruckandClaude Opus 5.5 committed 2026-10-10 00:04:37 +00:00
1 parent 5d69452db3
commit ccde7a4837
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@@ -4,7 +4,7 @@ use serde::{Deserialize, Serialize};
use solvecraft_geom::Vec3;
use truck_modeling as mt;
use crate::body::{Body, from_p3, p3, v3};
use crate::body::{Body, Solid, from_p3, p3, v3};
use crate::{KernelError, Result, guard};
#[derive(Clone, Copy, Debug, PartialEq, Eq, Serialize, Deserialize)]
@@ -162,6 +162,25 @@ thread_local! {
/// everything or an intersection of disjoint bodies. Results are checked against volume bounds
/// and retried with shifted copies and other tolerances when they fail or look wrong.
pub fn boolean(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
let r = boolean_whole(a, b, op);
// Bodies in several pieces: when the whole failed (or came out empty), a piece at a time.
let retry = match &r {
Err(_) => true,
Ok(None) => op != BoolOp::Intersect,
Ok(Some(_)) => false,
};
if retry && (a.solid.boundaries().len() > 1 || b.solid.boundaries().len() > 1) {
let (la, lb) = (a.lumps()?, b.lumps()?);
if (la.len() > 1 || lb.len() > 1)
&& let Ok(Some(x)) = by_lumps(la, lb, op)
{
return Ok(Some(x));
}
}
r
}
fn boolean_whole(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
a.require_brep("a boolean")?;
b.require_brep("a boolean")?;
let size = a.size().max(b.size());
@@ -339,6 +358,80 @@ pub fn boolean(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
Err(KernelError::Failed(format!("boolean {op:?}: {last}")))
}
/// A boolean of bodies given as their pieces; the result's pieces in one body.
fn by_lumps(la: Vec<Body>, lb: Vec<Body>, op: BoolOp) -> Result<Option<Body>> {
let boxes_meet = |x: &Body, y: &Body| -> bool {
let (Ok(mx), Ok(my)) = (x.tessellate(x.size() * 0.05 + 1e-3), y.tessellate(y.size() * 0.05 + 1e-3)) else { return true };
let (bx, by) = (mx.bounds(), my.bounds());
let g = (x.size() + y.size()) * 0.01;
bx.min.x <= by.max.x + g
&& by.min.x <= bx.max.x + g
&& bx.min.y <= by.max.y + g
&& by.min.y <= bx.max.y + g
&& bx.min.z <= by.max.z + g
&& by.min.z <= bx.max.z + g
};
let mut out: Vec<Body> = Vec::new();
match op {
BoolOp::Cut => {
for x in la {
let mut cur = Some(x);
for y in &lb {
cur = match cur {
Some(c) if boxes_meet(&c, y) => boolean(&c, y, BoolOp::Cut)?,
other => other,
};
}
out.extend(cur);
}
}
BoolOp::Intersect => {
for x in &la {
for y in &lb {
if boxes_meet(x, y)
&& let Some(r) = boolean(x, y, BoolOp::Intersect)?
{
out.push(r);
}
}
}
}
BoolOp::Union => {
out = la;
for y in lb {
let mut cur = y;
let mut rest = Vec::new();
for x in out {
if boxes_meet(&x, &cur) {
match boolean(&x, &cur, BoolOp::Union)? {
Some(u) if u.solid.boundaries().len() == 1 => cur = u,
_ => rest.push(x),
}
} else {
rest.push(x);
}
}
rest.push(cur);
out = rest;
}
}
}
join_pieces(out)
}
/// Bodies (apart from each other) as one body of several pieces.
pub(crate) fn join_pieces(pieces: Vec<Body>) -> Result<Option<Body>> {
match pieces.len() {
0 => Ok(None),
1 => Ok(pieces.into_iter().next()),
_ => {
let shells: Vec<mt::Shell> = pieces.iter().flat_map(|p| p.solid.boundaries().clone()).collect();
let solid = guard("pieces", || Solid::try_new(shells).map_err(|e| KernelError::Failed(e.to_string())))?;
Body::new(solid).map(Some)
}
}
}
/// Affine transform by a column-major 4×4 matrix (rotations, translations, reflections).
pub fn transform_matrix(body: &Body, m: [[f64; 4]; 4]) -> Result<Body> {
if m.iter().flatten().any(|x| !x.is_finite()) {