Trimming the base at an edge flange's setback snaps corners within tolerance onto the trim line and merges away the zero-width run a ledge as tall as the setback left along it, so the ledge goes with the strip as a lower one does. Splitting outline edges at other cells' corners now skips points within the model's tolerance of an end, so a ledge a little taller keeps its sliver and the bend runs under it, also off the axes. Both used to fail with "sew: a degenerate edge". Nothing new is stored.
A hole drilled along a panel, into its rim, has no place in the flat pattern
as a cut-out, so every such hole was refused. It is now kept as a bore of that
panel, in flat coordinates, and cut only from that panel's material when the
folded part and its flat pattern are built, so the sheet still unfolds and
folds back with it. A hole that would run into a bend, or cross a panel at an
angle, is still refused. The flat pattern lists the bores.
The action matrix worker takes ACTION_MATRIX_ONLY (just these actions) and
ACTION_MATRIX_UNFOLD (unfold and refold every sheet after each action) for
rechecking one group by hand.
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
- A fold's zone clipped across the root of a tab folded before on the same
line kept a sliver of no width there, which made the zone look like it
crossed a slanted edge. The one real piece is the zone now (#638).
- When the tabs a fold line spans can't take the side beyond them along,
because it joins the side that stays through other material (a tab on the
inside edge of an L, the fixed point on the far leg), the tabs' own ends fold
instead, the same part as with the fixed point on the near leg (#639).
Co-authored-by: jonaswre <3731681+jonaswre@users.noreply.github.com>
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
- A new cut was clipped against the panel with every one of its cut-outs, so
each hole of a perforation cost the square of all the holes before it and the
second cut of 500 ran out of the flat budget. A tool is now clipped against
only the cut-outs whose boxes meet its own (the same result).
- The planar booleans' point-in-loop test now skips loops whose box is clear of
the point, before the costly on-the-loop test; with a thousand holes that test
was most of the time.
The 1000-hole panel now takes about 15 s instead of failing.
Co-authored-by: jonaswre <3731681+jonaswre@users.noreply.github.com>
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
A hole drilled square to a flange's panel, not only the base's, is now a flat cut-out of the sheet: it unfolds with its panel to where the bend allowance puts it, shows in the flat pattern and DXF as a circle, and survives unfold and refold. A pocket tool spans the cut-outs already inside it (a counterbore's hole), so the order they are made in no longer matters. Fixes#560.
Convert to Sheet Metal now takes a solid or a shelled body by its bend edges (`bends`): the faces reached from the fixed face across those edges become the sheet, keeping the part's envelope, with the flat pattern by the rule's K-factor and radius. Other edges between sheet faces are cut open. The result works with edge flanges, cuts, Unfold/Refold, the flat pattern and DXF. A conversion without `bends` is the plate conversion as before. The optional `bends` field is noted under format 17. Fixes#647.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Sheet-metal cut-outs and base flange outlines drawn with ellipses, splines or text stay exact curves in the flat pattern and the unfolded body; the folded body follows them with tangent arcs within 0.001 mm (#659).
An edge flange picked on an edge that cut-outs have partly removed is built along what is left of that edge (the stretch nearest the pick), so each side of a notch can get its own flange.
Sheet metal rims and bend ends attach by name (<panel>:rim.<edge>, <flange>:rim.bend0/1), as do face profiles from sheet faces. A plain or counterbored Hole square to a panel is machined into the flat pattern. Boss, Lip, Rest and Snap Fit keep the body's history and name their own faces. Hole tools name their faces by the part they cut, and pattern copies as copies. A pattern's repeated fillets keep the body's history. Loft sides are named by their section curves. A piece Offset Face moved off its face's plane attaches by its own qualified name. Sides of a profile grown to overlap a flush body keep their sketch line's name, so walls a Join merged take a sketch (#681). Face sketch 75% -> 90%, offset plane 75% -> 90%, press-pull/extrude 64% -> 85% in the action matrix; baseline blessed.
Fixes#494, fixes#495, fixes#560, fixes#561, fixes#563, fixes#564, fixes#681.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
An edge flange whose edge ends at an inside corner of the base now trims only the strip under its own edge, so legs and stems past that corner stay. Where the bend ends beside more of the base, the rule's bend relief (relief_width, relief_depth) is cut into the base, or a note says why it was left out.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
An edge flange on another flange's far edge (a return) runs along that edge from end to end, following the parent's closed or cut-back corner, and returns of one feature close toward each other at convex base corners, mitred the rule's gap apart. Bends stop square where the mitre allows. Fixes#593.
Co-authored-by: NOWN-DEV <257771410+NOWN-DEV@users.noreply.github.com>
The bend table, flat pattern and DXF list a bend only where its centre line has material: a bend that cut-outs (or pockets that together go through the sheet) shorten keeps what is left, and one they split gets a row per piece, all with the bend's number.
Co-authored-by: NOWN-DEV <257771410+NOWN-DEV@users.noreply.github.com>
Faces that a sheet fold or unfold moves keep their names: points on a moved panel are taken back through the panel they lie on to where the sheet held them before the feature, and named from the faces there. Un-ignores the #535 regression test. Fixes#535.
Co-authored-by: jonaswre <jonas.wrede@beyondit.gmbh>
A stored fold whose fixed point drifts off the sheet after a parameter change keeps the side the point lies on and shows a warning instead of breaking the timeline. A new fold still refuses a fixed point off the sheet, atomically. Un-ignores the #370 regression test. Fixes#370.
Co-authored-by: jonaswre <jonas.wrede@beyondit.gmbh>
Sheet Metal Rules get a Corner Relief Shape (notch, round or rectangular), sized by the rule's corner relief, cut where two bends meet at a corner of the base. Notch, the default, keeps existing designs as they were. File format 16.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
A sketch on a flat face of a sheet metal body was refused ("this face has no exact planar
source"), so the only way was a plane frozen in space. When the sheet changes (a flange's
angle, the thickness), the frozen sketch stays behind: a cut from it fails on the slanted
flange or leaves a blind pocket in the thicker sheet.
`sketch.create` with a face of a sheet metal body now attaches the sketch to the panel the
face belongs to. It keeps the face's name, `sheet:<body>:<panel>:<top|bottom>` (the panel is
the base or a flange's feature tag), and takes the panel's exact plane from its flat region
and fold each time the model is evaluated, so the sketch follows the sheet through parameter
changes, unfold and refold. Its coordinates are the flat pattern's (the bottom face's y
mirrored). A face that is gone is reported as a lost attachment, never replaced by the
nearest face. The attachment follows a renamed or copied body, shows as `sheet_face` in the
command result and as its own status in Redefine Sketch Plane. `fixed: true` still freezes.
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
One edge flange feature gave all its flanges one height and one angle. A
part whose flanges lean differently took one feature per angle, and
flanges of separate features don't close toward each other, so its
corners stayed open.
- sheet.flange (edge): an entry of `edges` is a point [x, y, z] as before,
or {point, angle?, height?} whose angle and height (expressions, checked
like the feature's) replace the feature's for that edge. Bad input is
refused with the edge named. Before, the object form was read for its
point and the rest was ignored without a word.
- The feature stores its edges as FlangeEdge. An edge without values of
its own is written as the plain point it always was, so designs without
them are read and written as before; an unknown key in an edge is
refused, not dropped.
- The edges' values are feature inputs of their own (Edge angle, Edge
height, after the feature's), so parameters, renames and
parameters.change reach them. timeline.edit names the edges again when
it changes them, so each value stays with its edge.
- SheetBody::add_flanges_each trims every edge by its own setback and
adds the flanges. The corners between them close as between equal
flanges: the closing already works from the two flanges it joins (each
one's fold and leg), so the flat pattern follows by hand from the
angles, the heights and the rule (the tests derive it).
- The Flange dialog shows a row per picked edge with an angle and a
height box (empty: the dialog's value) once more than one edge is
picked, and brings them back on Edit Feature.
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
A cut-out made in the flat pattern could cross a bend only with edges
running along the bend or square to it: a round hole or a slanted slot
over a bend line failed to fold ("not supported yet: curved cut-outs
across a bend", "... cut-out edges running across a bend at an angle").
Sheet: a flat edge in a bend zone now folds whichever way it runs: along
the bend to a line, across it to an arc, and any other way to a curve on
the bend's cylinder (a slanted line to a helix). The curve is carried as
a chain of cubic Hermite pieces fitted within 1e-7 mm on both faces of
the sheet, with breaks that depend on the flat edge only, so the top
face, the bottom face and the wall share them. The wall between the two
chains is a ruled surface with radial rulings: the cut-out's wall stays
square to the sheet. The bend's own faces stay exact cylinders, now sized
to the whole boundary of their cell (a curved edge may bulge past its
corners).
Kernel: such an edge has no line, arc or conic form, so the sewing
interface gets EdgeSpec::Chain (a chain of cubic Bézier pieces: a cubic
B-spline with triple inner knots, its ends on the shared vertices) and
SurfSpec::Ruled (two chains joined by straight lines, so a wall built
from the chains holds them exactly). The sheet module's rev_edge becomes
EdgeSpec::reversed, so the new variant is handled where edges are
reversed.
The test for "along" and "across" is in millimetres (1e-6 mm at the
edge's ends) instead of relative 1e-9, so coordinates rounded by a script
fold as drawn.
Tests. Kernel: a box with one wall bulging as a cubic (chains of two
pieces at the bottom and the top, the wall ruled between them) sews to a
valid solid of the analytic volume, 27.6 (measured 27.59965); chains with
the wrong number of control points, a NaN or too many pieces, and a ruled
wall between chains of different piece counts, are refused. Sheet: a slot
turned 30° and a round hole across 72°, 90° and 108° bends fold to valid
solids that lose the cut-out's flat area times the thickness (K = 0.5:
400 and 100.53 mm³, measured within 0.02); a slanted flat edge folds to
its exact helix within 1e-7 mm (measured 1.9e-8) on both faces; lines
along and across the bend keep their line and arc. Engine:
fold_through_cut_outs now expects a round hole across a fold to fold, and
to unfold to the same round hole; the per-bend machining guard (#296)
sews a bend that carries a round cut-out, so a hole beside it cuts and a
hole in the bend is still refused.
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
Co-authored-by: bherbruck <brennen.herbruck@gmail.com>
The flat-pattern point budget (16 384) counted every cut-out by its 0.001 mm
chords, arcs included, so a plate with 240 round 4 mm holes (about 100 chords
each, 480 exact arcs) was refused with "sheet metal flat geometry exceeds the
bounded processing budget" when the holes were cut in the unfolded sheet. The
planar booleans work on exact lines and arcs whole, so those now count once
each; a sampled curve still counts its chords. A second limit keeps the
chords of everything, arcs included, at 65 536, the same figure the planar
boolean applies to the sampling it does itself, so the work stays bounded.
planar_region no longer samples an exact loop only to discard the result: the
complexity check right above it already covers the same budget.
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
Edge flanges meeting at a corner of the base were closed only at exactly
90°; at any other angle they stayed open (a V at 72°) and the rule's gap
was not used.
The flanges of one feature now close at any convex base corner and any
bend angle: each panel end is cut square to the sheet on a line in the
flat (slanted off 90°, stored as ext plus a new per-end slope) so the
edges nearest each other, on the inner faces, run parallel the rule's gap
apart about the plane bisecting the inner faces. The construction reads
the two flanges' own angles, so it holds for unequal ones as well. At 90°
it is the extension the old code gave (reference case 69-sm-tray is
unchanged). A corner that can't close (a gap under 0.01 mm, flanges
bending opposite ways, ends that would overlap in the flat pattern) stays
open, and the flange feature reports a warning that says where and why.
A flange of a later feature leaves the corner as it was (reference case
75-sm-bracket-holes: the earlier flange keeps its length).
Tested at 72° and 90° against a hand derivation, on a trapezoid, and
every 5° from 45° to 135° on a rectangle and a trapezoid (gap exact, one
flat region without hairline edges, one valid shell holding the flat
material).
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
The guard that refuses machining through bends sewed every bend zone and
nonparallel panel into one solid. Two bends meeting at an open corner relief
share only an edge, so that sew failed with "nonmanifold edge contact" and any
cut on the base was refused. Sew and test each piece on its own instead.
Reference case 75-sm-bracket-holes now passes; its known_failure mark is removed.
Fixes#296
Claude-Session: https://claude.ai/code/session_01RjGw4gA5ZvKrU8MQP6sBgT
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
A sheet-metal tray built at 2000 x 2500 mm with an edge flange on all four
edges (72° or 90°) and unfolded failed to rebuild when W and H went to
400 x 300, 600 x 450, or W alone to 400: "planar region arrangement failed
or exceeded its bounded processing budget". The same tray drawn at 400 x 300
unfolded, and growing it worked.
The sketch solved again after the change leaves its corners ~1e-13 mm off,
so the flanges inherit a hair of tilt and their panels and bend zones meet
the trimmed base within 1e-13 mm instead of exactly. The flat pattern is a
balanced union of those pieces, and the arrangement chains its output loops
within 10 tol. In a later round, ray parity classified a bend zone's edge
midpoint that lay level with a corner whose two lines did not quite meet:
the ray slipped through the gap without a crossing, the zone's edges counted
as inside the other operand and were dropped, and the outline no longer
closed. A rectangle turned by 1e-14 rad failed the same way.
inside_loop now closes the gap where one line ends and the next begins with
a straight connector while it counts crossings; exactly closed joints are
unaffected. Joints with an arc keep the arc's own endpoint rule, which
treats ends within its angular tolerance as on the ray (a connector there
double counted at a circle split into two arcs).
Co-authored-by: NOWN-DEV <257771410+NOWN-DEV@users.noreply.github.com>
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
* test: reproduce #264 (Sheet metal: collinear tabs cannot be folded or flanged together)
* fix(sheet): fold and flange tabs that sit side by side on one line (#264)
A fold's bend zone and a flange's setback were cut with an infinite line, so
a second tab on the same line blocked a fold ('slanted or curved edge') and
two tab-end flanges in one feature shared one trimmed edge (nonmanifold).
When the zone falls apart into pieces, fold only the pieces the fold points
span, each as its own bend; trim a flange's setback only from the material
along its own edge, and attach each flange to the edge it was picked on.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01RjGw4gA5ZvKrU8MQP6sBgT
---------
Co-authored-by: bherbruck <brennen.herbruck@gmail.com>
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
* test: reproduce #263 (sheet.fold accepts a fixed point that is not on the sheet)
* fix(sheet): refuse a fold's fixed point that lies off the sheet's material (#263)
A fixed point inside a cut-out or outside the base outline (in the panel's
thickness) silently picked a side. Refuse it with an error that names the
point; side-face picks and points on other panels keep working.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01RjGw4gA5ZvKrU8MQP6sBgT
---------
Co-authored-by: bherbruck <brennen.herbruck@gmail.com>
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
* test: reproduce #262 (sheet.fold: bend zone reaching the blank outline is reported as a slanted or curved edge)
* fix(sheet): name the bend zone reaching an outline corner instead of blaming a slanted edge (#262)
A fold whose bend zone contains a corner of the panel outline (a fold at a
tab's root) was reported as crossing a slanted or curved edge. Name the
corner and how far to move the fold line to clear it.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01RjGw4gA5ZvKrU8MQP6sBgT
---------
Co-authored-by: bherbruck <brennen.herbruck@gmail.com>
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
Record ownership transfers in the timeline so earlier Join/Cut membership,
world placement, machining data and styles survive component moves, edits,
independent copying, undo and reopening. Preserve pending positions in history
snapshots and keep constructor transfers ordered during feature redefinition.
Retain shallow sheet pockets and exact planar intersection islands through
unfold/refold, with depth-aware flat previews and DXF export. Store explicit
3D wire coordinate spaces and migrate known legacy provenance without moving
saved points or analytic fits.
Infer unique eligible cylindrical Emboss targets, align Revolve manipulators
with actual extent geometry, and discard obsolete preview errors after input
correction. Certify constructed and immutable imported face styles using exact
source metadata while preserving legacy face names. Upgrade designs to format10
with bounded validation and geometry-preserving legacy migration.
Persist typed sketch dimensions and bounded ordered configuration rules in format 8. Use exact occurrence paths and source identity for editing, movement, appearance, and mass. Preserve sheet material regions through cutting, folding, and exact DXF export; retain nested cavities and material islands.
Validation: cargo xtask ci passed, including 368 engine tests, 178 UI tests, 68 UI scenarios, 136 kernel tests, and the 10-crate wasm check. Actual preview workflows and legacy format-7 origin-corner reopening were inspected.
Use egui pointer ownership for viewport navigation and picking, view-cube
interaction, and sketch-dimension hover. Cover scrolling, model selection,
and cube interaction under floating dialogs, including after they close.
Shield constraint glyph and move-gizmo highlights from overlapping UI too.
Clear strict Clippy warnings and use the same saved path in the recent-file
scenario on Windows and Unix.
Fixes#87
NOWN-DEV