Flat-pattern DXF for a laser shop: layers by role, dashed bend lines, bend notes, a file per body (#1324)

Closes #1284. sheet.export_dxf writes layers by role (OUTLINE, CUT, TEXT or ETCH, dashed BEND_UP/BEND_DOWN, optional BEND_NOTES, POCKET_<side>_Z…_MM and PERFORATION), inner contours before the outline; text: cut|etch, bend_notes and note_height, per_body files. Letters are derived from the timeline, nothing new is saved (format unchanged). I merged main in (the export's parameter list keeps main's pocket layer names). Checked on main + this branch: cargo check --workspace, the engine cmd::sheet tests (160) and the io DXF tests.

crates/engine/src/cmd/sheet_dxf_tests.rs

@@ -1,4 +1,6 @@
-//! The flat pattern's DXF keeps ellipses and free-form curves as ELLIPSE and SPLINE entities.
+//! The flat pattern's DXF keeps ellipses and free-form curves as ELLIPSE and SPLINE entities, and
+//! a laser-cutting shop can use it as it is: layers by role, bend notes, letters cut or etched,
+//! one file per sheet body.
 
 use std::f64::consts::{PI, TAU};
 
@@ -16,11 +18,18 @@ fn run(s: &mut Session, id: &str, p: Value) -> Value {
 
 /// A 100 × 60 base flange (the default 2.5 mm rule) with `curves` drawn in a sketch and cut through it.
 fn plate_with(curves: &[(&str, Value)]) -> Session {
-    let mut s = Session::default();
+    plate_in(Session::default(), curves)
+}
+
+/// A 100 × 60 base flange in `s` (of its rule), with `curves` drawn in a sketch and cut through it.
+fn plate_in(mut s: Session, curves: &[(&str, Value)]) -> Session {
     run(&mut s, "sketch.create", json!({"plane": "XY", "name": "Base"}));
     run(&mut s, "sketch.rectangle.two_point", json!({"p0": [0, 0], "p1": [100, 60]}));
     run(&mut s, "sketch.finish", json!({}));
     run(&mut s, "sheet.flange", json!({"sketch": "Base"}));
+    if curves.is_empty() {
+        return s;
+    }
     run(&mut s, "sketch.create", json!({"plane": "XY", "name": "Cut"}));
     for (command, params) in curves {
         run(&mut s, command, params.clone());
@@ -30,6 +39,31 @@ fn plate_with(curves: &[(&str, Value)]) -> Session {
     s
 }
 
+/// A session whose active rule is 2 mm sheet with an inner bend radius of 1 mm.
+fn sheet_of_2mm() -> Session {
+    let mut s = Session::default();
+    run(&mut s, "sheet.manage_rules", json!({"name": "Sheet2", "thickness": "2 mm", "k_factor": "0.5", "bend_radius": "1 mm", "active": true}));
+    s
+}
+
+/// A 100 × 60 tray of 2 mm sheet with `curves` cut through its base: three 20 mm walls bend up and
+/// one bends down.
+fn tray_with(curves: &[(&str, Value)]) -> Session {
+    let mut s = plate_in(sheet_of_2mm(), curves);
+    run(&mut s, "sheet.flange", json!({"edges": [[50, 0, 2], [100, 30, 2], [50, 60, 2]], "height": 20}));
+    run(&mut s, "sheet.flange", json!({"edges": [[0, 30, 2]], "height": 20, "flip": true}));
+    s
+}
+
+/// What a tray is marked with: a Ø5 hole, a 20 × 5 slot and the label "AB-12", 10 mm high at (20, 28).
+fn marks() -> Vec<(&'static str, Value)> {
+    vec![
+        ("sketch.circle.center", json!({"center": [15, 15], "diameter": 5})),
+        ("sketch.rectangle.two_point", json!({"p0": [70, 40], "p1": [90, 45]})),
+        ("sketch.text", json!({"text": "AB-12", "at": [20, 28], "height": 10})),
+    ]
+}
+
 fn export(s: &mut Session, params: Value) -> String {
     run(s, "sheet.export_dxf", params)["dxf"].as_str().unwrap_or_default().to_string()
 }
@@ -217,5 +251,272 @@ fn bend_lines_and_layers_are_still_there() {
     let es = entities(out["dxf"].as_str().unwrap_or_default());
     let on = |layer: &str| es.iter().filter(|e| e.1.contains(&(8, layer.to_string()))).count();
     assert_eq!(on("BEND_UP") + on("BEND_DOWN"), out["bends"].as_u64().unwrap_or(0) as usize);
-    assert!(on("BEND_UP") + on("BEND_DOWN") > 0 && count(&es, "ELLIPSE") == 1 && on("OUTLINE") == es.len() - on("BEND_UP") - on("BEND_DOWN"));
+    // The ellipse is a cut-out, on CUT; the outline is the plate's.
+    assert!(on("BEND_UP") + on("BEND_DOWN") > 0 && count(&es, "ELLIPSE") == 1 && on("CUT") == 1);
+    assert_eq!(on("OUTLINE") + on("CUT"), es.len() - on("BEND_UP") - on("BEND_DOWN"));
+}
+
+/// The layer an entity is on.
+fn layer_of(e: &Entity) -> String {
+    e.1.iter().find(|(c, _)| *c == 8).map(|(_, v)| v.clone()).unwrap_or_default()
+}
+
+/// The text of an entity's group code.
+fn string(e: &Entity, code: i32) -> String {
+    e.1.iter().find(|(c, _)| *c == code).map(|(_, v)| v.clone()).unwrap_or_default()
+}
+
+/// What the entities of a layer are, without their handles and the layer: to compare layers of two files.
+fn on_layer(es: &[Entity], layer: &str) -> Vec<(String, Vec<(i32, String)>)> {
+    es.iter().filter(|e| layer_of(e) == layer).map(|e| (e.0.clone(), e.1.iter().filter(|(c, _)| ![5, 8].contains(c)).cloned().collect())).collect()
+}
+
+/// The LAYER table: name → (colour, linetype).
+fn layer_table(dxf: &str) -> std::collections::BTreeMap<String, (i64, String)> {
+    let lines: Vec<&str> = dxf.lines().collect();
+    let pairs: Vec<(i32, &str)> = lines.chunks(2).filter_map(|c| Some((c.first()?.trim().parse().ok()?, c.get(1)?.trim()))).collect();
+    let start = pairs.iter().position(|p| *p == (2, "LAYER")).unwrap_or(0);
+    let mut records: Vec<Vec<(i32, &str)>> = Vec::new();
+    for p in pairs.iter().skip(start + 1) {
+        match *p {
+            (0, "ENDTAB") => break,
+            (0, _) => records.push(Vec::new()),
+            _ => {
+                if let Some(record) = records.last_mut() {
+                    record.push(*p);
+                }
+            }
+        }
+    }
+    records
+        .iter()
+        .filter_map(|r| {
+            let get = |code: i32| r.iter().find(|(c, _)| *c == code).map(|(_, v)| *v);
+            Some((get(2)?.to_string(), (get(62)?.parse().ok()?, get(6)?.to_string())))
+        })
+        .collect()
+}
+
+fn vec2(v: &Value) -> Vec2 {
+    Vec2::new(v[0].as_f64().unwrap_or(f64::NAN), v[1].as_f64().unwrap_or(f64::NAN))
+}
+
+#[test]
+fn the_flat_pattern_is_on_layers_by_role_and_inner_contours_come_first() {
+    let mut s = tray_with(&marks());
+    let out = run(&mut s, "sheet.export_dxf", json!({}));
+    let dxf = out["dxf"].as_str().unwrap_or_default();
+    let es = entities(dxf);
+    let on = |layer: &str| es.iter().filter(|e| layer_of(e) == layer).collect::<Vec<_>>();
+    // OUTLINE: the tray's outer contour alone, one entity for each of its segments (lines and arcs).
+    let regions = s.model.state().sheets[0].flat_regions().unwrap_or_default();
+    let plate =
+        regions.iter().max_by(|a, b| a.area().total_cmp(&b.area())).map(|r| r.outer.clone()).unwrap_or(solidcraft_geom::Loop2 { segs: Vec::new() });
+    assert_eq!(on("OUTLINE").len(), solidcraft_io::loop_shapes(&plate).len());
+    assert!(on("OUTLINE").iter().all(|e| e.0 == "LINE" || e.0 == "ARC"), "{:?}", on("OUTLINE").iter().map(|e| &e.0).collect::<Vec<_>>());
+    // CUT: what is cut out inside it that is no text: the Ø5 hole as one CIRCLE, the slot's four lines.
+    let cut = on("CUT");
+    assert_eq!((count_of(&cut, "CIRCLE"), count_of(&cut, "LINE"), cut.len()), (1, 4, 5), "{:?}", cut.iter().map(|e| &e.0).collect::<Vec<_>>());
+    // TEXT: the letters of "AB-12" and the counters of A and B, all within the label's box (5 letters
+    // of at most 10 mm from (20, 28)).
+    let letters = on("TEXT");
+    assert!(letters.len() > 20, "{} letter entities", letters.len());
+    for e in &letters {
+        let p = point(e, 10);
+        assert!(p.x > 19.0 && p.x < 80.0 && p.y > 27.0 && p.y < 39.0, "{} at {p:?}", e.0);
+    }
+    // The bend lines by direction: three walls up, one down.
+    assert_eq!((on("BEND_UP").len(), on("BEND_DOWN").len(), out["bends"].as_u64()), (3, 1, Some(4)));
+    // Inner contours are written before the outline, so a program that follows the file cuts inside-out.
+    let last_inner = es.iter().rposition(|e| matches!(layer_of(e).as_str(), "CUT" | "TEXT"));
+    let first_outline = es.iter().position(|e| layer_of(e) == "OUTLINE");
+    let (Some(last_inner), Some(first_outline)) = (last_inner, first_outline) else { panic!("{last_inner:?} {first_outline:?}") };
+    assert!(last_inner < first_outline, "an inner contour at {last_inner}, the outline from {first_outline}");
+    // The layers, with the colours and linetypes the guide gives; nothing else is declared.
+    let want = [
+        ("0", 7, "Continuous"),
+        ("OUTLINE", 7, "Continuous"),
+        ("CUT", 4, "Continuous"),
+        ("TEXT", 2, "Continuous"),
+        ("BEND_UP", 1, "DASHED"),
+        ("BEND_DOWN", 5, "DASHED"),
+    ];
+    assert_eq!(layer_table(dxf), want.map(|(n, c, l)| (n.to_string(), (c, l.to_string()))).into_iter().collect());
+}
+
+/// How many entities of `kind` there are among `list`.
+fn count_of(list: &[&Entity], kind: &str) -> usize {
+    list.iter().filter(|e| e.0 == kind).count()
+}
+
+#[test]
+fn letters_can_be_etched_instead_of_cut() {
+    let mut s = tray_with(&marks());
+    let cut = entities(&export(&mut s, json!({})));
+    let etched_dxf = export(&mut s, json!({"text": "etch"}));
+    let etched = entities(&etched_dxf);
+    // The same contours, on ETCH instead of TEXT: nothing of them is cut.
+    assert!(!on_layer(&cut, "TEXT").is_empty());
+    assert_eq!(on_layer(&etched, "ETCH"), on_layer(&cut, "TEXT"));
+    assert!(on_layer(&etched, "TEXT").is_empty());
+    // The hole and the slot are no text: they stay where they were, as do the outline and the bends.
+    for layer in ["OUTLINE", "CUT", "BEND_UP", "BEND_DOWN"] {
+        assert_eq!(on_layer(&etched, layer), on_layer(&cut, layer), "{layer}");
+    }
+    let layers = layer_table(&etched_dxf);
+    assert_eq!(layers.get("ETCH"), Some(&(6, "Continuous".to_string())));
+    assert!(!layers.contains_key("TEXT"));
+    // `cut` is the default, and a value that is neither is refused.
+    assert_eq!(export(&mut s, json!({"text": "cut"})), export(&mut s, json!({})));
+    assert!(s.execute("sheet.export_dxf", &json!({"text": "fill"})).is_err());
+}
+
+#[test]
+fn engraved_text_is_etched_and_other_pockets_keep_their_depth_layer() {
+    let mut s = Session::default();
+    run(&mut s, "sketch.create", json!({"plane": "XY", "name": "Base"}));
+    run(&mut s, "sketch.rectangle.two_point", json!({"p0": [0, 0], "p1": [100, 60]}));
+    run(&mut s, "sketch.finish", json!({}));
+    run(&mut s, "sheet.flange", json!({"sketch": "Base"}));
+    run(&mut s, "sketch.create", json!({"plane": "XY", "name": "Marks"}));
+    run(&mut s, "sketch.rectangle.two_point", json!({"p0": [70, 40], "p1": [90, 45]}));
+    run(&mut s, "sketch.text", json!({"text": "AB-12", "at": [20, 28], "height": 10}));
+    run(&mut s, "sketch.finish", json!({}));
+    // Part way through the sheet: pockets, 1 mm deep from the bottom.
+    run(&mut s, "solid.extrude", json!({"sketch": "Marks", "distance": 1, "operation": "cut"}));
+    let dxf = export(&mut s, json!({}));
+    let es = entities(&dxf);
+    // The rectangle is a pocket of the depth its layer names; the letters are a marking, on ETCH.
+    let pocket = "POCKET_BOTTOM_Z0.000000_TO_1.000000_MM";
+    let on = |layer: &str| es.iter().filter(|e| layer_of(e) == layer).collect::<Vec<_>>();
+    assert_eq!((count_of(&on(pocket), "LINE"), on(pocket).len()), (4, 4));
+    let letters = on("ETCH");
+    assert!(letters.len() > 20, "{} letter entities", letters.len());
+    for e in &letters {
+        let p = point(e, 10);
+        assert!(p.x > 19.0 && p.x < 80.0 && p.y > 27.0 && p.y < 39.0, "{} at {p:?}", e.0);
+    }
+    let layers = layer_table(&dxf);
+    assert!(layers.contains_key(pocket) && layers.contains_key("ETCH") && !layers.contains_key("TEXT"), "{layers:?}");
+    // `text` is about letters cut through: it changes nothing here.
+    assert_eq!(on_layer(&entities(&export(&mut s, json!({"text": "etch"}))), "ETCH"), on_layer(&es, "ETCH"));
+}
+
+#[test]
+fn a_bend_note_sits_beside_each_bend_line_when_asked_for() {
+    let mut s = tray_with(&[]);
+    let flat = run(&mut s, "sheet.flat_pattern", json!({}));
+    let bends = flat["bends"].as_array().cloned().unwrap_or_default();
+    assert_eq!(bends.len(), 4);
+    // Not unless asked for: a program that follows the file would etch them.
+    let plain = export(&mut s, json!({}));
+    assert!(entities(&plain).iter().all(|e| e.0 != "TEXT") && !layer_table(&plain).contains_key("BEND_NOTES"));
+    let dxf = export(&mut s, json!({"bend_notes": true}));
+    let notes: Vec<Entity> = entities(&dxf).into_iter().filter(|e| e.0 == "TEXT").collect();
+    assert_eq!(notes.len(), 4);
+    assert!(notes.iter().all(|e| layer_of(e) == "BEND_NOTES"));
+    assert_eq!(layer_table(&dxf).get("BEND_NOTES"), Some(&(8, "Continuous".to_string())));
+    for b in &bends {
+        // The walls bend by 90° round an inner radius of 1 mm: "B1 UP 90° R1" (`%%d` is the degree sign).
+        let up = b["direction"] == "up";
+        let text = format!("B{} {} 90%%d R1", b["bend"].as_u64().unwrap_or(0), if up { "UP" } else { "DOWN" });
+        let Some(note) = notes.iter().find(|e| string(e, 1) == text) else {
+            panic!("no note `{text}` among {:?}", notes.iter().map(|e| string(e, 1)).collect::<Vec<_>>())
+        };
+        // Centred (72 = 1), 3 mm high, parallel to the line: along x it reads left to right, along y upwards.
+        let (start, end) = (vec2(&b["start"]), vec2(&b["end"]));
+        let angle = if (end - start).x.abs() > (end - start).y.abs() { 0.0 } else { 90.0 };
+        assert!(values(note, 72) == [1.0] && values(note, 40) == [3.0] && (values(note, 50)[0] - angle).abs() < 1e-9, "{note:?}");
+        // On the left of the way it reads, half its height from the middle of the line.
+        let off = point(note, 11) - (start + end) * 0.5;
+        assert!(off.dist(Vec2::from_angle(angle.to_radians()).perp() * 1.5) < 1e-9, "{text}: {off:?}");
+    }
+    // The height is the caller's.
+    let tall = entities(&export(&mut s, json!({"bend_notes": true, "note_height": 5})));
+    let note = tall.iter().find(|e| e.0 == "TEXT");
+    assert!(note.is_some_and(|e| values(e, 40) == [5.0]));
+}
+
+/// Two sheet bodies: a lid and, 200 mm away, a side wall with one bend.
+fn lid_and_wall() -> Session {
+    let mut s = Session::default();
+    for (sketch, p0, p1, body) in [("Lid", [0, 0], [100, 60], "Lid"), ("Wall", [200, 0], [250, 40], "Side Wall")] {
+        run(&mut s, "sketch.create", json!({"plane": "XY", "name": sketch}));
+        run(&mut s, "sketch.rectangle.two_point", json!({"p0": p0, "p1": p1}));
+        run(&mut s, "sketch.finish", json!({}));
+        run(&mut s, "sheet.flange", json!({"sketch": sketch, "body_name": body}));
+    }
+    run(&mut s, "sheet.flange", json!({"edges": [[225, 0, 2.5]], "height": 15, "body": "Side Wall"}));
+    s
+}
+
+#[test]
+fn each_sheet_body_can_have_a_file_of_its_own() {
+    let mut s = lid_and_wall();
+    let r = run(&mut s, "sheet.export_dxf", json!({"per_body": true}));
+    let files = r["files"].as_array().cloned().unwrap_or_default();
+    assert_eq!(files.iter().map(|f| f["body"].as_str().unwrap_or_default()).collect::<Vec<_>>(), ["Lid", "Side Wall"]);
+    assert_eq!(files.iter().map(|f| f["bends"].as_u64()).collect::<Vec<_>>(), [Some(0), Some(1)]);
+    // Each is the file `body` asks for: the lid's has no bend line, the wall's has its one.
+    for f in &files {
+        let single = export(&mut s, json!({"body": f["body"]}));
+        assert_eq!(f["dxf"].as_str(), Some(single.as_str()), "{}", f["body"]);
+    }
+    let bend_lines = |f: &Value| entities(f["dxf"].as_str().unwrap_or_default()).iter().filter(|e| layer_of(e) == "BEND_UP").count();
+    assert_eq!((bend_lines(&files[0]), bend_lines(&files[1])), (0, 1));
+    // With a path, each body is written to a file named after it, beside the path, and no text comes back.
+    let dir = solidcraft_io::vfs::temp_dir().join(format!("solidcraft-dxf-per-body-{}", std::process::id()));
+    let _ = std::fs::remove_dir_all(&dir);
+    std::fs::create_dir_all(&dir).unwrap_or_default();
+    let path = dir.join("panel.dxf").to_string_lossy().to_string();
+    let r = run(&mut s, "sheet.export_dxf", json!({"per_body": true, "path": path}));
+    let written = r["files"].as_array().cloned().unwrap_or_default();
+    let names: Vec<_> = written
+        .iter()
+        .map(|f| std::path::Path::new(f["path"].as_str().unwrap_or_default()).file_name().map(|n| n.to_string_lossy().to_string()))
+        .collect();
+    assert_eq!(names, [Some("panel-Lid.dxf".to_string()), Some("panel-Side Wall.dxf".to_string())]);
+    for (f, written) in files.iter().zip(&written) {
+        assert!(written.get("dxf").is_none());
+        let on_disk = std::fs::read_to_string(written["path"].as_str().unwrap_or_default()).unwrap_or_default();
+        assert_eq!(f["dxf"].as_str(), Some(on_disk.as_str()));
+    }
+    let _ = std::fs::remove_dir_all(&dir);
+}
+
+#[test]
+fn bad_export_options_are_refused_not_ignored() {
+    let mut s = tray_with(&[]);
+    for p in [
+        json!({"text": "fill"}),
+        json!({"text": 1}),
+        json!({"bend_notes": "yes"}),
+        json!({"bend_notes": 1}),
+        json!({"note_height": 0}),
+        json!({"note_height": -3}),
+        json!({"note_height": 1e9}),
+        json!({"note_height": "tall"}),
+        json!({"per_body": "yes"}),
+        json!({"per_body": true, "body": "Body1"}),
+    ] {
+        assert!(s.execute("sheet.export_dxf", &p).is_err(), "{p}");
+    }
+    // Nothing was left half done.
+    assert!(s.execute("sheet.export_dxf", &json!({})).is_ok());
+}
+
+#[test]
+fn the_file_of_a_body_is_named_after_it_and_no_two_share_a_name() {
+    // (Windows writes the separator it adds as `\`.)
+    let names = |path: &str, bodies: &[&str]| -> Vec<String> {
+        super::body_paths(path, &bodies.iter().map(|b| b.to_string()).collect::<Vec<_>>()).into_iter().map(|p| p.replace('\\', "/")).collect()
+    };
+    assert_eq!(names("out/panel.dxf", &["Lid", "Side Wall"]), ["out/panel-Lid.dxf", "out/panel-Side Wall.dxf"]);
+    // The extension is the path's, and .dxf when it has none.
+    assert_eq!(names("out/panel", &["Lid"]), ["out/panel-Lid.dxf"]);
+    assert_eq!(names("panel.DXF", &["Lid"]), ["panel-Lid.DXF"]);
+    // What a file name cannot hold becomes `_`; a name that is nothing but that stays a name.
+    assert_eq!(names("p.dxf", &["a/b:c", "  ", "wall."]), ["p-a_b_c.dxf", "p-body.dxf", "p-wall.dxf"]);
+    // Two bodies that would share a file (in any case) get a number.
+    assert_eq!(names("p.dxf", &["Lid", "lid", "LID", "Lid_2"]), ["p-Lid.dxf", "p-lid_2.dxf", "p-LID_3.dxf", "p-Lid_2_2.dxf"]);
 }