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OneCAD/crates/engine/src/tests/fixtures/battery-tpu-case.solidcraft
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Erikas e519fbd14d Meshing: start a face's boundary walk at a point the surface search finds (#882) (#1157) 
When projecting a face's boundary loop onto its surface fails from an unhinted first point, the walk is retried once from the first point an unhinted search does find; a walk that succeeds is unchanged. A fillet strip on an extended surface now meshes, so the rim cut in the reported case builds in one boolean.
2026-10-14 14:56:33 -04:00

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{
"format": "solidcraft/18",
"name": "Battery TPU Case",
"units": "mm",
"params": [
{
"name": "batt_w",
"expr": "290 mm",
"unit": "mm",
"comment": "Battery flat top/bottom width",
"model": false
},
{
"name": "batt_bulge",
"expr": "10 mm",
"unit": "mm",
"comment": "Side bulge past the top/bottom corners",
"model": false
},
{
"name": "batt_h",
"expr": "92 mm",
"unit": "mm",
"comment": "Battery height",
"model": false
},
{
"name": "peak_left",
"expr": "27 mm",
"unit": "mm",
"comment": "Height of the left side's widest point",
"model": false
},
{
"name": "peak_right",
"expr": "batt_h - peak_left",
"unit": "mm",
"comment": "Height of the right side's widest point",
"model": false
},
{
"name": "batt_len",
"expr": "198 mm",
"unit": "mm",
"comment": "Battery length",
"model": false
},
{
"name": "tab_w",
"expr": "15 mm",
"unit": "mm",
"comment": "Connector tab width (from the left top corner)",
"model": false
},
{
"name": "tab_depth",
"expr": "5.5 mm",
"unit": "mm",
"comment": "Connector tab protrusion",
"model": false
},
{
"name": "ramp_len",
"expr": "35 mm",
"unit": "mm",
"comment": "Ramp from tab back to the wall",
"model": false
},
{
"name": "ramp_blend_wall",
"expr": "80 mm",
"unit": "mm",
"comment": "Blend radius ramp to wall",
"model": false
},
{
"name": "ramp_blend_tab",
"expr": "40 mm",
"unit": "mm",
"comment": "Blend radius tab to ramp",
"model": false
},
{
"name": "wall",
"expr": "3 mm",
"unit": "mm",
"comment": "TPU wall thickness",
"model": false
},
{
"name": "r_big",
"expr": "5 mm",
"unit": "mm",
"comment": "Fillet on the 4 long profile edges (inside and outside)",
"model": false
},
{
"name": "r_small",
"expr": "1 mm",
"unit": "mm",
"comment": "Fillet on all other edges (inside and outside)",
"model": false
},
{
"name": "pleat_depth",
"expr": "10 mm",
"unit": "mm",
"comment": "Accordion pleat depth at the open edge",
"model": false
},
{
"name": "pleat_pitch",
"expr": "16 mm",
"unit": "mm",
"comment": "Accordion fold pitch",
"model": false
},
{
"name": "clear",
"expr": "1 mm",
"unit": "mm",
"comment": "Overshoot so trimming tools never sit on a face",
"model": false
},
{
"name": "d1",
"expr": "batt_w",
"unit": "mm",
"model": true
},
{
"name": "d2",
"expr": "batt_w",
"unit": "mm",
"model": true
},
{
"name": "d3",
"expr": "batt_h",
"unit": "mm",
"model": true
},
{
"name": "d4",
"expr": "batt_bulge",
"unit": "mm",
"model": true
},
{
"name": "d5",
"expr": "peak_right",
"unit": "mm",
"model": true
},
{
"name": "d6",
"expr": "batt_bulge",
"unit": "mm",
"model": true
},
{
"name": "d7",
"expr": "peak_left",
"unit": "mm",
"model": true
},
{
"name": "d10",
"expr": "batt_w + 2 * batt_bulge + 10 * clear",
"unit": "mm",
"model": true
},
{
"name": "d11",
"expr": "clear",
"unit": "mm",
"model": true
},
{
"name": "d12",
"expr": "batt_len",
"unit": "mm",
"model": true
},
{
"name": "d13",
"expr": "batt_len + tab_depth",
"unit": "mm",
"model": true
},
{
"name": "d14",
"expr": "batt_w / 2 - tab_w",
"unit": "mm",
"model": true
},
{
"name": "d15",
"expr": "ramp_len",
"unit": "mm",
"model": true
},
{
"name": "d16",
"expr": "ramp_blend_wall",
"unit": "mm",
"model": true
},
{
"name": "d17",
"expr": "ramp_blend_tab",
"unit": "mm",
"model": true
}
],
"features": [
{
"id": 1,
"name": "BatteryProfile",
"suppressed": false,
"type": "sketch",
"plane": {
"type": "custom",
"plane": {
"origin": [
0.0,
0.0,
0.0
],
"x_dir": [
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0.0,
0.0
],
"y_dir": [
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0.0,
1.0
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}
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"sketch": {
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0.0
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92.0
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"fixed": false
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{
"id": "l1.end",
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{
"id": "l2.end",
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],
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{
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145.0,
0.0
],
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{
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0.0
],
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{
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{
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0.0
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{
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0.0
],
"fixed": true,
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{
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"pos": [
0.0,
-100.0
],
"fixed": true,
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],
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"link": "j2"
}
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"construction": false
},
{
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{
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{
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"constraints": [
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},
{
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{
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{
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{
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"param": "d4"
},
{
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"value": 65.0,
"param": "d5"
},
{
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"value": 10.0,
"param": "d6"
},
{
"id": "k12",
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"q": 6,
"value": 27.0,
"param": "d7"
}
],
"links": [
{
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"kind": "project",
"source": {
"type": "sketch_axis",
"name": "x"
}
},
{
"id": "j2",
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"source": {
"type": "sketch_axis",
"name": "y"
}
}
],
"counters": {
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"p": 4
}
}
},
{
"id": 2,
"name": "BatteryStock",
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"body_names": [
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],
"param_names": [
"d8"
],
"type": "extrude",
"sketch": 1,
"profiles": {
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},
"extent": {
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"direction": "positive"
},
"operation": "new_body"
},
{
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"param_names": [
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"name": "XY"
},
"distance": "-clear"
},
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],
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{
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{
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{
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],
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"construction": false
},
{
"id": "l2",
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},
{
"id": "l3",
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{
"id": "l4",
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{
"id": "l5",
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"construction": false
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{
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},
{
"id": "l7",
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"construction": true,
"link": "j1"
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{
"id": "a1",
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}
],
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{
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{
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{
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},
{
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},
{
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"value": 320.0,
"param": "d10"
},
{
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"param": "d11"
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{
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{
"id": "k14",
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},
{
"id": "k15",
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{
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},
{
"id": "k17",
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},
{
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{
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],
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},
{
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"type": "extrude",
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"direction": "positive"
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"targets": [
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},
{
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"suppressed": false,
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"type": "move",
"bodies": [
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],
"translate": [
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"0"
],
"copy": true
},
{
"id": 6,
"name": "CaseShell",
"suppressed": false,
"param_names": [
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"face_names": [
"F2:side:l4"
],
"type": "shell",
"faces": [
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0.0,
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]
],
"thickness": "wall",
"body": "Case",
"direction": "outside"
},
{
"id": 7,
"name": "Fillet1",
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],
"edge_names": [
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"F2:side:l1@F5.1|F2:side:l2@F5.1",
"F2:side:l2@F5.1|F2:side:l3@F5.1",
"F6:inner:F2:side:l5@F5.1|F6:inner:F2:side:l6@F5.1",
"F6:inner:F2:side:l1@F5.1|F6:inner:F2:side:l6@F5.1",
"F6:inner:F2:side:l1@F5.1|F6:inner:F2:side:l2@F5.1",
"F6:inner:F2:side:l2@F5.1|F6:inner:F2:side:l3@F5.1"
],
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],
"radius": "r_big",
"body": "Case"
},
{
"id": 8,
"name": "Fillet2",
"suppressed": false,
"param_names": [
"d24"
],
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