fix: reject planar joins that displace original faces

crates/engine/src/tests/robustness.rs

@@ -202,10 +202,30 @@ fn fillet_into_an_earlier_round() {
     }
 }
 
-/// Seeds that run clean: no failure, no invalid body, no volume going the wrong way.
+/// Clean seeds and the original seed 5 edge contact, now rejected without distortion.
 #[test]
 fn fixed_seeds_run_clean() {
     for seed in FIXED_SEEDS {
+        if *seed == 5 {
+            // Seed 5 originally joined these boxes along only an edge. Accepting
+            // it required silently shifting the tool; that is now invalid input.
+            let mut s = Session::default();
+            run(&mut s, "solid.box", json!({"length": 25, "width": 15, "height": 10}));
+            let error = s
+                .execute(
+                    "solid.box",
+                    &json!({
+                        "corner": [25, 2.5, 10], "length": 17.5, "width": 17.5,
+                        "height": 20, "operation": "join"
+                    }),
+                )
+                .unwrap_err();
+            assert!(error.to_string().contains("zero-thickness edge contact"), "{error}");
+            assert!((total_volume(&s) - 3750.0).abs() < 1e-6);
+            assert_eq!(s.model.state().bodies.len(), 1);
+            assert!(s.model.state().bodies.first().unwrap().body.validity().is_empty());
+            continue;
+        }
         let r = fuzz::run(*seed, 8);
         assert!(!r.outcome.is_bug(), "seed {seed}: {:?}\n{}", r.outcome, r.script());
     }

crates/kernel/src/ops.rs

@@ -171,7 +171,7 @@ 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);
+    let mut 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,
@@ -183,12 +183,52 @@ pub fn boolean(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
         if (la.len() > 1 || lb.len() > 1)
             && let Ok(Some(x)) = by_lumps(la, lb, op)
         {
-            return Ok(Some(x));
+            r = Ok(Some(x));
         }
     }
+    if op == BoolOp::Union
+        && let Ok(Some(body)) = &r
+        && !preserves_planar_surfaces(a, b, body)
+    {
+        // Numerical retries must not quietly alter a planar design's dimensions.
+        // Prefer the exact polygon result; reject an edge-only pinch if it cannot
+        // form a closed solid without displacing either operand.
+        r = match crate::polybool::planar_boolean(a, b, op) {
+            Ok(Some(exact)) if preserves_planar_surfaces(a, b, &exact) => Ok(Some(exact)),
+            _ => Err(KernelError::Invalid(
+                "join cannot preserve the original faces; check for zero-thickness edge contact or add intentional overlap".into(),
+            )),
+        };
+    }
     r
 }
 
+/// Every face of an all-planar union must remain on an operand's original plane.
+/// Curved operands keep their existing surface-specific boolean handling.
+fn preserves_planar_surfaces(a: &Body, b: &Body, result: &Body) -> bool {
+    guard("validate planar union", || Ok(planar_surfaces_match(a, b, result))).unwrap_or(false)
+}
+
+fn planar_surfaces_match(a: &Body, b: &Body, result: &Body) -> bool {
+    let planes: Option<Vec<(Vec3, f64)>> = a
+        .solid
+        .face_iter()
+        .chain(b.solid.face_iter())
+        .map(|f| {
+            let mt::Surface::Plane(p) = f.oriented_surface() else { return None };
+            let n = p.normal();
+            let n = Vec3::new(n.x, n.y, n.z).normalized()?;
+            Some((n, n.dot(from_p3(p.origin()))))
+        })
+        .collect();
+    let Some(planes) = planes else { return true };
+    let tol = (a.size().max(b.size()) * 1e-9).max(1e-9);
+    result.solid.face_iter().all(|f| {
+        matches!(f.oriented_surface(), mt::Surface::Plane(_))
+            && planes.iter().any(|(n, d)| f.vertex_iter().all(|v| (n.dot(from_p3(v.point())) - d).abs() <= tol))
+    })
+}
+
 /// Smallest side of the box where the bodies' vertex boxes overlap (infinite when they don't).
 fn meeting_size(a: &Body, b: &Body) -> f64 {
     let bbox = |x: &Body| {

crates/kernel/src/tests.rs

@@ -317,6 +317,37 @@ fn planar_booleans_with_coincident_faces() {
     assert!(rel(measure(&i).unwrap().volume, 250.0) < 1e-9);
 }
 
+#[test]
+fn stepped_logo_join_never_moves_faces_to_hide_an_edge_pinch() {
+    let mut body = box_solid(Vec3::ZERO, Vec3::new(10.0, 20.0, 10.0)).unwrap();
+    for (i, (lo, hi)) in
+        [(Vec3::new(0.0, 0.0, 10.0), Vec3::new(10.0, 10.0, 20.0)), (Vec3::new(-10.0, 0.0, 10.0), Vec3::new(0.0, 10.0, 20.0))].into_iter().enumerate()
+    {
+        let tool = box_solid(lo, hi).unwrap();
+        body = boolean(&body, &tool, BoolOp::Union).unwrap().unwrap();
+        assert!(body.validity().is_empty());
+        let m = measure(&body).unwrap();
+        assert!((m.volume - (3000.0 + i as f64 * 1000.0)).abs() < 1e-6, "join {i}: {}", m.volume);
+        assert!((m.bbox.max.z - 20.0).abs() < 1e-9, "join {i}: {}", m.bbox.max.z);
+        let tops =
+            body.faces(0.01).unwrap().iter().filter(|f| f.plane_normal.is_some_and(|n| n.z > 0.999999) && (f.centroid.z - 20.0).abs() < 1e-9).count();
+        assert_eq!(tops, 1, "join {i}: the top must be a single selectable face");
+        assert!(m.bbox.min.dist(Vec3::new(if i == 0 { 0.0 } else { -10.0 }, 0.0, 0.0)) < 1e-9);
+        assert!(m.bbox.max.dist(Vec3::new(10.0, 20.0, 20.0)) < 1e-9);
+    }
+    let tool = box_solid(Vec3::new(-10.0, 10.0, 10.0), Vec3::new(0.0, 20.0, 20.0)).unwrap();
+    let error = boolean(&body, &tool, BoolOp::Union).unwrap_err();
+    assert!(error.to_string().contains("zero-thickness edge contact"), "{error}");
+    // An intentional overlap removes the pinch without any automatic displacement.
+    let overlap = box_solid(Vec3::new(-10.0, 10.0, 10.0), Vec3::new(0.1, 20.0, 20.0)).unwrap();
+    let joined = boolean(&body, &overlap, BoolOp::Union).unwrap().unwrap();
+    assert!(joined.validity().is_empty());
+    let m = measure(&joined).unwrap();
+    assert!((m.volume - 5010.0).abs() < 1e-6);
+    assert!(m.bbox.min.dist(Vec3::new(-10.0, 0.0, 0.0)) < 1e-9);
+    assert!(m.bbox.max.dist(Vec3::new(10.0, 20.0, 20.0)) < 1e-9);
+}
+
 #[test]
 fn corner_boss_on_stepped_case_has_one_exact_top_face() {
     let outer = box_solid(Vec3::new(-50.0, -25.0, 0.0), Vec3::new(50.0, 25.0, 25.0)).unwrap();