Converted sheets take the rule's corner relief between walls and its bend relief where a bend ends beside more of the fixed face, and a wall on part of an edge bends only where it stands. Noted under format 21; nothing new is saved.
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.
A Convert to Sheet Metal bend point can now lie on a bend modelled with its radius (a cylinder tangent to two flat faces) or in the middle of a chamfer; either becomes one bend at the faces' virtual sharp, with the rule's radius. Holes and engravings carry over. Bend points on edges convert as before. Recorded under format 21. Tests in cmd::sheet::convert_tests; the sheet-metal guide is updated.
* Action matrix regressions of #1255: knuckle rounds, thin holes, a 45° flange hole, an axis after an edit
- Curve blends: past the end of a curved edge the run of sections along the end
tangent wrapped round the ring of centres; it is shortened while it still
crosses the end face (the hinge knuckle's cap rounds at 0.728 mm).
- Boolean retry guard: each body's volume is measured finer than its smallest
radius, and a volume out of bounds is measured again ten times finer before
it refuses (a 0.133 mm drill measured -30272 mm³; a plastic part's coarse
mesh was off by more than the slack).
- Sheet metal: a drill cap's certificate allows the evaluation noise its fitted
tilt shows (a hole square to a 45° flange).
- Construction geometry on a named face uses the face found by name, not a
second pick at its nearest point (an axis through a corner round after a
parameter moved it).
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
* Retry guard: measure the target, tool and result at one tolerance
Measured at different tolerances, the chords' error on the faces they share
didn't cancel: a blind hole in a long D-profile bar measured 20 mm³ more than
the bar.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
* Action matrix baseline from this branch's full run: 37 actions pass again, none fewer
Blessed with cargo xtask action-matrix --from DIR --bless from the 16 shards of
run 38673859774.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
---------
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
Adds sheet.perforate: round holes on a staggered or square grid over the flat sheet, kept clear of edges, cut-outs and bend zones. The holes go to the flat pattern, the DXF and the measured volume rather than the B-rep, so a panel can carry many thousands of them.
Convert to Sheet Metal without bend edges refused every plate whose bounding-box diagonal reached a thousand times its thickness ("no outline on that face"), and just under that limit a hole smaller than the mesh's sag fell out of the outline and the DXF. The outline's tolerance is now at most a tenth of the thickness: a thin plate is meshed again at that tolerance. Nothing new is stored. Tests: long thin strips, sheets thousands of times longer than thick, and a strip keeping holes down to 1 mm.
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>
The plate check compared the face outline's area (from the tessellation, so each hole was a polygon of chords) with the exact volume, and refused plates with a few small holes. Where the outline runs along a cylinder about the plate's normal it is now an arc of that circle; coaxial pieces of one radius are one wall, so a hole split into two, three or four faces is one circle. The check passes with its tolerance unchanged, and the flat pattern and its DXF carry one CIRCLE per hole (ARC for rounded corners and slot ends).
A round blank now converts too, so unfold_cut_refold_and_convert checks the refusal with a block thicker at one end instead of a rod.
- 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>
On a large thin sheet the probes around the fixed point stepped clean through
the sheet (twice the mesh tolerance of a 465 mm part is more than its 0.8 mm
thickness), so a point exactly on the face touched no material and the fold
was refused. The probes now also step a quarter of the thickness.
Co-authored-by: jonaswre <3731681+jonaswre@users.noreply.github.com>
Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
A lip picked on a face that isn't a shelled body's rim, such as the Sample Plate's top
face with its two holes and the boss standing on it, ran its band round the largest inner
edge. That was the boss's foot, so the band stood against the boss's wall and the join
failed with a boolean error about curved faces.
The band now goes round the face's opening (an inner edge with no material just over the
face inside it). A rim face that has a smaller hole in it still works. A face whose inner
edges are only where other features stand on it, or whose openings are alike in size (a
plate's holes), is refused with a plain message that names the rim face it needs.
Fixes#892.
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).
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>
A Box cut, or a Cylinder cut whose axis is the sheet's normal, machines a sheet metal body like the extrude cut of its footprint: through the sheet it's a cut-out (a cylinder an exact round one in the flat pattern and DXF), part way it's a pocket. Primitives at other angles or across a bend are still refused. Un-ignores the #541 regression test. Fixes#541.
Co-authored-by: jonaswre <jonas.wrede@beyondit.gmbh>
sheet.fold tests its fixed point against the whole sheet body, so a point far above or below the sheet is refused atomically, while a point on any face (including a flange's leg) still works. A stored fold whose point ends up in the air recomputes, keeps its side and warns. Un-ignores the #371 regression test. Fixes#371.
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>
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>
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>
Why: every reference a user makes to a face or edge (fillet and chamfer
edges, sketches on faces, shell/draft/offset faces, joints, appearances)
is stored as a name and found again after any upstream edit. Those names
were re-derived by sampling points of each face and voting, and pieces
of a split face were numbered by where their centres lay. After an
upstream edit that splits, merges, mirrors or shrinks a face, a fillet
or sketch could silently re-attach to the wrong face, and nothing told
the user. The kernel now reports exact history for its operations, so
names follow it and fail loudly instead of guessing.
- crates/doc/src/lineage.rs: a feature's kernel histories composed into
one lineage over nameable operands (bodies before the feature, moved
copies, shell cavities, tools named by role: sketch curve, cap, box
side, imported face). Instrumented: extrude/revolve/sweep/loft tools,
join/cut/intersect, lumps after a cut, fillet/chamfer, shell, draft,
split face/body, pattern/mirror (bodies and features), combine,
boundary fill, move/scale, offset/delete face, thread, import.
- crates/doc/src/history_names.rs: names from lineage; split pieces told
apart by the faces only they touch (F2:top#[F2:side:l4,F4:side:l4]),
merged faces answer to every name (aliases), lump bodies ordered by
their faces' names instead of shell order.
- crates/doc/src/name_lookup.rs, piece_names.rs: references resolve by
exact name, alias or bounding faces, else nearest piece with a
warning; names worked out from geometry (operations without history)
are reported when only geometry decided.
- Format 14: names stored by older formats get a legacy mark and are
found as the build that saved them found them (some geometric names
name a face history names differently: a tube's outer wall was named
after its inner circle). New corpus file saved by 9a979cf.
- kernel: Body::lumps carries each piece's history over the whole.
- Adversarial tests: split, merge, mirrored twins, shrink to a sliver,
moving cut with body pieces, history-less bodies, certified sketch.
- docs/book/src/dev/naming.md describes the real mechanism and why.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01J53sR6gEaVt56soFDpTck8
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.
NOWN-DEV