//! Booleans of bodies with coincident planar faces, by moving faces apart first. //! //! The mesh-based intersection cannot handle faces that lie in the same plane, nor the edges //! lying in them. A face whose neighbours stand perpendicular to it (any extruded or //! box-like part) can be pushed along its normal exactly, by rebuilding it and stretching or //! shrinking its neighbours. Then: //! - cut and intersect: the tool's coincident face moves out of the way (outward when the //! bodies are on the same side of the plane, away from the target when they touch back to //! back), which leaves the result unchanged; //! - union of faces facing the same way: both faces move outward by different amounts, the //! union is taken, and the slab beyond the plane is cut off (now a transversal cut); //! - union of faces back to back: the tool's face moves into the target, which overlaps it. use std::collections::HashMap; use solvecraft_geom::Vec3; use truck_modeling::{self as mt, builder}; use crate::body::{Body, Solid, from_p3, p3, v3}; use crate::{BoolOp, KernelError, Result, guard}; #[derive(Clone, Copy, Debug)] struct PlaneFace { n: Vec3, d: f64, } fn planes(b: &Body) -> Vec<(usize, PlaneFace)> { b.solid .face_iter() .enumerate() .filter_map(|(i, f)| match f.oriented_surface() { mt::Surface::Plane(p) => { let n = p.normal(); let n = Vec3::new(n.x, n.y, n.z).normalized()?; Some((i, PlaneFace { n, d: n.dot(from_p3(p.origin())) })) } _ => None, }) .collect() } /// Push the planar faces of `b` lying in the plane (n, d) — n their outward normal — along n /// by `delta` (negative: inward). Their neighbours must stand perpendicular to the plane. pub(crate) fn push_faces(b: &Body, n: Vec3, d: f64, delta: f64) -> Result { // The exact rebuild, unless it came out unsound (a curved side it couldn't re-sweep). match push_faces_exact(b, n, d, delta) .and_then(|r| if r.validity().is_empty() { Ok(r) } else { Err(KernelError::Failed("pushing a face: an unsound result".into())) }) { Ok(r) => Ok(r), // Faces of planes and cylinders: every face follows (any neighbours). Err(e) => { let size = b.size(); let tol = (size * 1e-7).max(1e-9) * 10.0; let planes: Vec = b .solid .face_iter() .map(|f| match f.oriented_surface() { mt::Surface::Plane(p) => { let m = p.normal(); let m = Vec3::new(m.x, m.y, m.z); m.dot(n) > 1.0 - 1e-9 && (n.dot(from_p3(p.origin())) - d).abs() < tol } _ => false, }) .collect(); crate::offset::offset_body(b, |i, _| if planes.get(i).copied().unwrap_or(false) { delta } else { 0.0 }).map_err(|_| e) } } } pub(crate) fn push_faces_exact(b: &Body, n: Vec3, d: f64, delta: f64) -> Result { let size = b.size(); let tol = (size * 1e-7).max(1e-9); let fail = |m: &str| KernelError::Failed(format!("pushing a face: {m}")); guard("push face", || { let solid = b.deep_copy(); let shift = n * delta; let mat = mt::Matrix4::from_translation(v3(shift)); let mut shells = Vec::new(); for sh in solid.boundaries() { let faces: Vec = sh.face_iter().cloned().collect(); let on_plane = |f: &mt::Face| match f.oriented_surface() { mt::Surface::Plane(p) => { let m = p.normal(); let m = Vec3::new(m.x, m.y, m.z); m.dot(n) > 1.0 - 1e-9 && (n.dot(from_p3(p.origin())) - d).abs() < tol * 10.0 } _ => false, }; let moving: Vec = (0..faces.len()).filter(|i| faces.get(*i).is_some_and(on_plane)).collect(); if moving.is_empty() { shells.push(sh.clone()); continue; } // Vertices and edges of the moving faces. let mut vmap: HashMap = HashMap::new(); let mut emap: HashMap = HashMap::new(); for i in &moving { let f = faces.get(*i).ok_or_else(|| fail("face"))?; for v in f.vertex_iter() { vmap.entry(v.id()).or_insert_with(|| builder::vertex(p3(from_p3(v.point()) + shift))); } } for i in &moving { let f = faces.get(*i).ok_or_else(|| fail("face"))?; for e in f.edge_iter() { if emap.contains_key(&e.id()) { continue; } let (a, bb) = ( vmap.get(&e.absolute_front().id()).ok_or_else(|| fail("vertex"))?, vmap.get(&e.absolute_back().id()).ok_or_else(|| fail("vertex"))?, ); let curve = mt::Transformed::transformed(&e.curve(), mat); emap.insert(e.id(), mt::Edge::new(a, bb, curve)); } } // Edges leaving the plane at moved vertices: straight, along n. for f in &faces { for e in f.edge_iter() { if emap.contains_key(&e.id()) { continue; } let (fa, fb) = (e.absolute_front(), e.absolute_back()); let (ma, mb) = (vmap.get(&fa.id()), vmap.get(&fb.id())); if ma.is_none() && mb.is_none() { continue; } if !matches!(e.curve(), mt::Curve::Line(_)) { return Err(fail("a neighbouring edge is not straight")); } let dir = (from_p3(fb.point()) - from_p3(fa.point())).normalized().ok_or_else(|| fail("zero edge"))?; if dir.cross(n).len() > 1e-9 { return Err(fail("a neighbouring face is not perpendicular")); } let (na, nb) = (ma.cloned().unwrap_or_else(|| fa.clone()), mb.cloned().unwrap_or_else(|| fb.clone())); if (from_p3(nb.point()) - from_p3(na.point())).dot(dir) <= tol { return Err(fail("the face would pass its opposite side")); } emap.insert(e.id(), builder::line(&na, &nb)); } } let rebuild_wires = |f: &mt::Face| -> Vec { f.absolute_boundaries() .iter() .map(|w| { w.edge_iter() .map(|e| match emap.get(&e.id()) { Some(ne) => { if e.front() == e.absolute_front() { ne.clone() } else { ne.inverse() } } None => e.clone(), }) .collect::>() .into() }) .collect() }; use mt::{ParametricSurface3D, SearchNearestParameter}; let mut out: Vec = Vec::new(); for (i, f) in faces.iter().enumerate() { let touches = f.edge_iter().any(|e| emap.contains_key(&e.id())); if !touches { out.push(f.clone()); continue; } let wires = rebuild_wires(f); let surface = if moving.contains(&i) { mt::Transformed::transformed(&f.surface(), mat) } else if matches!(f.surface(), mt::Surface::Plane(_)) { f.surface() } else { // A curved side: sweep its edge in the plane along the new height. let base = f.edge_iter().find_map(|e| { emap.get(&e.id()).filter(|_| { let (a, bb) = (from_p3(e.absolute_front().point()), from_p3(e.absolute_back().point())); (n.dot(a) - d).abs() < tol * 10.0 && (n.dot(bb) - d).abs() < tol * 10.0 }) }); let base = base.ok_or_else(|| fail("a curved side without an edge in the plane"))?; let height = f.vertex_iter().map(|v| n.dot(from_p3(v.point())) - d).fold(0.0f64, |m, x| if x.abs() > m.abs() { x } else { m }); let swept: mt::Face = builder::tsweep(base, v3(n * (height - delta))); let mut s = swept.surface(); // Same normal as the old side at a point both share. let probe = f.vertex_iter().map(|v| from_p3(v.point())).fold(Vec3::ZERO, |a, x| a + x) / f.vertex_iter().count().max(1) as f64; let old = f.surface(); if let (Some((u0, v0)), Some((u1, v1))) = (old.search_nearest_parameter(p3(probe), None, 100), s.search_nearest_parameter(p3(probe), None, 100)) { let (a, bb) = (old.normal(u0, v0), s.normal(u1, v1)); if mt::InnerSpace::dot(a, bb) < 0.0 { s = mt::Invertible::inverse(&s); } } s }; let mut nf = mt::Face::try_new(wires, surface).map_err(|e| fail(&e.to_string()))?; if !f.orientation() { nf.invert(); } out.push(nf); } shells.push(out.into()); } let s = Solid::try_new(shells).map_err(|e| fail(&e.to_string()))?; Body::new(s) }) } /// A box covering everything beyond the plane (n, d) by up to `depth`. fn slab_beyond(n: Vec3, d: f64, depth: f64, extent: f64) -> Result { let u = n.any_perp(); let w = n.cross(u); let o = n * d; let pl = solvecraft_geom::Plane::new(o, u, w).ok_or_else(|| KernelError::Failed("slab plane".into()))?; let sq = solvecraft_geom::Loop2::polygon(&[ solvecraft_geom::Vec2::new(-extent, -extent), solvecraft_geom::Vec2::new(extent, -extent), solvecraft_geom::Vec2::new(extent, extent), solvecraft_geom::Vec2::new(-extent, extent), ]); let r = solvecraft_geom::Region2 { outer: sq, holes: vec![] }; crate::extrude(&pl, &[r], 0.0, depth)?.pop().ok_or_else(|| KernelError::Failed("slab".into())) } /// Do the bodies have planar faces in a common plane? pub(crate) fn has_coincident_faces(a: &Body, b: &Body) -> bool { let tol = (a.size().max(b.size()) * 1e-7).max(1e-9); let (pa, pb) = (planes(a), planes(b)); pa.iter().any(|(_, x)| pb.iter().any(|(_, y)| x.n.dot(y.n).abs() > 1.0 - 1e-9 && (x.d - y.d * x.n.dot(y.n)).abs() < tol * 10.0)) } /// Retry a failed boolean with coincident planar faces pushed apart. `None` when there are no /// coincident faces or the faces can't be pushed. pub(crate) fn boolean_apart(a: &Body, b: &Body, op: BoolOp) -> Option>> { let size = a.size().max(b.size()); let tol = (size * 1e-7).max(1e-9); let (pa, pb) = (planes(a), planes(b)); let mut same: Vec<(Vec3, f64)> = Vec::new(); let mut back: Vec<(Vec3, f64)> = Vec::new(); for (_, x) in &pa { for (_, y) in &pb { if (x.d - y.d * x.n.dot(y.n)).abs() < tol * 10.0 && x.n.dot(y.n).abs() > 1.0 - 1e-9 { let list = if x.n.dot(y.n) > 0.0 { &mut same } else { &mut back }; if !list.iter().any(|(n, d)| n.dot(x.n) > 1.0 - 1e-9 && (d - x.d).abs() < tol * 10.0) { list.push((x.n, x.d)); } } } } if same.is_empty() && back.is_empty() { return None; } let (d1, d2) = (size * 0.0137, size * 0.0229); let run = || -> Result> { let (mut a2, mut b2) = (a.clone(), b.clone()); for (n, d) in &same { // b's face points along n too. b2 = push_faces(&b2, *n, *d, d2)?; if op == BoolOp::Union { a2 = push_faces(&a2, *n, *d, d1)?; } } for (n, d) in &back { // a's face points along n; b's face points along −n at the same plane (−d). let shift = if op == BoolOp::Union && crate::ops::narrowing_bores() { // Pushed into `a`, b's face must have a's material behind it all over and that // deep: over a hole in a's face (a narrowed bore's rim over the other body's // bore) it would fill the hole, through a thin wall it would stick out the far // side. Only checked inside `bore_union`, which then tries its other way; a // general check turns some joins that come out slightly wrong today (a pad // half past an edge) into failures, until such faces can be split first. [d2, d2 * 0.25, d2 * 0.0625] .into_iter() .find(|depth| backed(a, b, -*n, -*d, *depth)) .ok_or_else(|| KernelError::Failed("pushing a face: part of it lies over a hole or past the edge of the other body".into()))? } else if op == BoolOp::Union { d2 } else { -d2 }; b2 = push_faces(&b2, -*n, -*d, shift)?; } let Some(mut r) = crate::ops::boolean(&a2, &b2, op)? else { return Ok(None) }; if op == BoolOp::Union { for (n, d) in &same { let slab = slab_beyond(*n, *d, d1.max(d2) * 3.0, size * 4.0)?; match crate::ops::boolean(&r, &slab, BoolOp::Cut)? { Some(x) => r = x, None => return Ok(None), } } } Ok(Some(r)) }; Some(run()) } /// Has `a` material behind every part of b's faces in the plane (m, d) (m their outward /// normal, pointing into `a`), to `depth`? Checked at points inside the faces' triangles. fn backed(a: &Body, b: &Body, m: Vec3, d: f64, depth: f64) -> bool { let size = a.size().max(b.size()); let tol = (size * 1e-7).max(1e-9) * 10.0; let faces: Vec = planes(b).into_iter().filter(|(_, p)| p.n.dot(m) > 1.0 - 1e-9 && (p.d - d).abs() < tol).map(|(i, _)| i).collect(); let (Ok(ma), Ok(mb)) = (a.tessellate_with(size * 1e-3, true), b.tessellate_with(size * 1e-3, true)) else { return false }; let inside = ma.inside_index(); let mut points = Vec::new(); for (t, fi) in mb.triangles.iter().zip(&mb.tri_face) { if !faces.contains(&(*fi as usize)) { continue; } let Some([p, q, r]) = mb.tri(t) else { continue }; let c = (p + q + r) / 3.0; points.extend([c, c.lerp(p, 0.8), c.lerp(q, 0.8), c.lerp(r, 0.8)]); if points.len() > 4000 { break; } } !points.is_empty() && points.iter().all(|p| [0.05, 0.5, 1.0].iter().all(|k| inside.contains(*p + m * (depth * k)))) } /// Union of bodies that touch along one identical planar face, back to back (a body joined /// with its mirror image): the two faces go and the shells are stitched along their edges. /// `None` when no such pair of faces exists. pub(crate) fn glue(a: &Body, b: &Body) -> Option> { use mt::{BoundedCurve, ParametricCurve}; let size = a.size().max(b.size()); let tol = (size * 1e-7).max(1e-9) * 10.0; let key = |p: Vec3| ((p.x / tol).round() as i64, (p.y / tol).round() as i64, (p.z / tol).round() as i64); let mid = |e: &mt::Edge| { let c = e.curve(); let (t0, t1) = c.range_tuple(); from_p3(c.subs((t0 + t1) * 0.5)) }; // Matching faces: same plane, opposite normals, the same edges. let (pa, pb) = (planes(a), planes(b)); let fa_list: Vec<&mt::Face> = a.solid.face_iter().collect(); let fb_list: Vec<&mt::Face> = b.solid.face_iter().collect(); for (ia, x) in &pa { for (ib, y) in &pb { if x.n.dot(y.n) > -1.0 + 1e-9 || (x.d + y.d).abs() > tol { continue; } let (Some(fa), Some(fb)) = (fa_list.get(*ia), fb_list.get(*ib)) else { continue }; let ea: Vec = fa.edge_iter().collect(); let eb: Vec = fb.edge_iter().collect(); if ea.len() != eb.len() { continue; } // B edge → the matching A edge. let mut map: HashMap = HashMap::new(); let mut vmap: HashMap = HashMap::new(); let mut ok = true; for e in &eb { let ends = (key(from_p3(e.absolute_front().point())), key(from_p3(e.absolute_back().point()))); let m = key(mid(e)); let hit = ea.iter().find(|f| { let fe = (key(from_p3(f.absolute_front().point())), key(from_p3(f.absolute_back().point()))); (fe == ends || fe == (ends.1, ends.0)) && key(mid(f)) == m }); let Some(f) = hit else { ok = false; break; }; let same = key(from_p3(f.absolute_front().point())) == ends.0; map.insert(e.id(), if same { f.absolute_clone() } else { f.absolute_clone().inverse() }); let (fa_v, fb_v) = if same { (f.absolute_front().clone(), f.absolute_back().clone()) } else { (f.absolute_back().clone(), f.absolute_front().clone()) }; vmap.insert(e.absolute_front().id(), fa_v); vmap.insert(e.absolute_back().id(), fb_v); } if !ok { continue; } return Some(guard("glue", || { let fail = |m: &str| KernelError::Failed(format!("joining touching faces: {m}")); // B's other edges, rebuilt on A's vertices where they meet the seam. let mut edges: HashMap = map.clone(); for e in b.solid.edge_iter() { if edges.contains_key(&e.id()) { continue; } let (f0, f1) = (e.absolute_front(), e.absolute_back()); if !vmap.contains_key(&f0.id()) && !vmap.contains_key(&f1.id()) { edges.insert(e.id(), e.absolute_clone()); continue; } let v0 = vmap.get(&f0.id()).cloned().unwrap_or_else(|| f0.clone()); let v1 = vmap.get(&f1.id()).cloned().unwrap_or_else(|| f1.clone()); edges.insert(e.id(), mt::Edge::new(&v0, &v1, e.curve())); } let mut faces: Vec = fa_list.iter().enumerate().filter(|(i, _)| i != ia).map(|(_, f)| (*f).clone()).collect(); for (i, f) in fb_list.iter().enumerate() { if i == *ib { continue; } let wires: Vec = f .absolute_boundaries() .iter() .map(|w| { w.edge_iter() .filter_map(|e| edges.get(&e.id()).map(|ne| if e.front() == e.absolute_front() { ne.clone() } else { ne.inverse() })) .collect::>() .into() }) .collect(); let mut nf = mt::Face::try_new(wires, f.surface()).map_err(|e| fail(&e.to_string()))?; if !f.orientation() { nf.invert(); } faces.push(nf); } let solid = Solid::try_new(vec![faces.into()]).map_err(|e| fail(&e.to_string()))?; Body::new(crate::heal::heal(solid, size)) })); } } None } /// A cylindrical face: its index, a point on the axis, the unit axis and the radius. #[derive(Clone, Copy, Debug)] struct CylFace { index: usize, origin: Vec3, axis: Vec3, radius: f64, } fn cylinders(b: &Body) -> Vec { (0..b.face_count()) .filter_map(|index| match crate::face_surface(b, index)? { crate::FaceSurface::Cylinder { origin, axis, radius } => Some(CylFace { index, origin, axis, radius }), _ => None, }) .collect() } /// Do the two cylinders lie on the same surface? fn same_cylinder(x: &CylFace, y: &CylFace, tol: f64) -> bool { let off = y.origin - x.origin; x.axis.dot(y.axis).abs() > 1.0 - 1e-9 && (x.radius - y.radius).abs() < tol && (off - x.axis * off.dot(x.axis)).len() < tol } /// Do the bodies have cylindrical faces on a common cylinder? pub(crate) fn has_coincident_cylinders(a: &Body, b: &Body) -> bool { let tol = (a.size().max(b.size()) * 1e-7).max(1e-9) * 10.0; let cb = cylinders(b); cylinders(a).iter().any(|x| cb.iter().any(|y| same_cylinder(x, y, tol))) } /// Union of bodies with bores on a common cylinder (a drain pad's bore around the drain hole /// it is joined over). The mesh intersection can't take the coincident walls, so the tool's /// bore is narrowed (its walls pushed toward the axis, now clear of the target's), the bodies /// are joined, and the cylinder of the original bore is cut out again over the tool's length. /// Recutting is valid only where that cylinder holds no material of either body. The /// samples are plausibility checks; a whole-boundary guard rejects additional boundaries /// crossing the recut. Original common-bore trims retain the legacy eligibility policy. /// This is not a general emptiness or Boolean-equivalence certificate. Each direction /// returns a result only when `accept` takes it; otherwise this returns `None`. pub(crate) fn bore_union(a: &Body, b: &Body, accept: &dyn Fn(&Body) -> bool) -> Option { let size = a.size().max(b.size()); let tol = (size * 1e-7).max(1e-9) * 10.0; let mtol = size * 2e-3; let (ma, mb) = (a.tessellate_with(mtol, true).ok()?, b.tessellate_with(mtol, true).ok()?); let (ia, ib) = (ma.inside_index(), mb.inside_index()); let empty = |p: Vec3| !ia.contains(p) && !ib.contains(p); let (ca, cb) = (cylinders(a), cylinders(b)); // (body to narrow, its mesh and inside test, the other body, their faces on the cylinder). let ways = [(b, &mb, &ib, a, &cb, &ca), (a, &ma, &ia, b, &ca, &cb)]; for (tool, mesh, inside, target, ct, co) in ways { for c in ct { if !co.iter().any(|o| same_cylinder(c, o, tol)) { continue; } let bore: Vec = ct.iter().filter(|x| same_cylinder(c, x, tol)).map(|x| x.index).collect(); // The tool's extent along the axis on that cylinder, and whether it is a bore (the // material outside it) at a point of the face. let (mut t0, mut t1) = (f64::INFINITY, f64::NEG_INFINITY); let mut probe = None; for (t, fi) in mesh.triangles.iter().zip(&mesh.tri_face) { if !bore.contains(&(*fi as usize)) { continue; } let Some(ps) = mesh.tri(t) else { continue }; for p in ps { let s = (p - c.origin).dot(c.axis); t0 = t0.min(s); t1 = t1.max(s); } if probe.is_none() { probe = Some((ps[0] + ps[1] + ps[2]) / 3.0); } } let Some(q) = probe else { continue }; if !(t1 - t0 > tol && c.radius > tol) { continue; } let along = c.origin + c.axis * (q - c.origin).dot(c.axis); let Some(radial) = (q - along).normalized() else { continue }; let on = along + radial * c.radius; let e = (c.radius * 0.05).max(size * 1e-4); if !(inside.contains(on + radial * e) && !inside.contains(on - radial * e)) { continue; } // The cylinder over the tool's length holds no material of either body. let (u, w) = (c.axis.any_perp(), c.axis.cross(c.axis.any_perp())); let at = |s: f64, r: f64, ang: f64| c.origin + c.axis * s + (u * ang.cos() + w * ang.sin()) * r; let clear = (1..=9).all(|i| { let s = t0 + (t1 - t0) * f64::from(i) / 10.0; empty(at(s, 0.0, 0.0)) && (0..8).all(|k| { let ang = f64::from(k) * std::f64::consts::FRAC_PI_4 + 0.3; empty(at(s, c.radius * 0.5, ang)) && empty(at(s, c.radius * 0.9, ang)) }) }); if !clear { continue; } // Past an end where the space is empty well beyond the radius too, the cut runs on a // little (so its cap doesn't lie in a face's plane). Not where the other body's bore // goes on: the cut's side would lie on its wall. let ext = size * 0.01; let past = |s: f64| { empty(at(s, 0.0, 0.0)) && (0..8).all(|k| { let ang = f64::from(k) * std::f64::consts::FRAC_PI_4 + 0.3; empty(at(s, c.radius * 0.9, ang)) && empty(at(s, c.radius * 1.1, ang)) && empty(at(s, c.radius * 1.5, ang)) }) }; let lo = if past(t0 - ext * 0.5) && past(t0 - ext) { t0 - ext } else { t0 }; let hi = if past(t1 + ext * 0.5) && past(t1 + ext) { t1 + ext } else { t1 }; // The samples above are plausibility checks, not proof that an // arbitrarily thin web is absent. Every additional current boundary // must be wholly clear of the recut; unsupported trims refuse. let other_bore: Vec = co.iter().filter(|x| same_cylinder(c, x, tol)).map(|x| x.index).collect(); if crate::bore_guard::boundaries_clear(tool, &bore, c.origin, c.axis, c.radius, lo, hi, tol).is_none() || crate::bore_guard::boundaries_clear(target, &other_bore, c.origin, c.axis, c.radius, lo, hi, tol).is_none() { continue; } let d = (c.radius * 0.2).min(size * 0.01); let run = || -> Result> { let narrowed = crate::offset::offset_body(tool, |i, _| if bore.contains(&i) { d } else { 0.0 })?; if !narrowed.validity().is_empty() { return Err(KernelError::Failed("narrowing a bore: an unsound result".into())); } let Some(joined) = crate::ops::boolean(target, &narrowed, BoolOp::Union)? else { return Ok(None) }; let cut = crate::build::cylinder(at(lo, 0.0, 0.0), c.axis, c.radius, hi - lo)?; crate::ops::boolean(&joined, &cut, BoolOp::Cut) }; match run() { Ok(Some(r)) if accept(&r) => return Some(r), _ => continue, } } } None }