Booleans about twice as fast: point-in-mesh tests through a per-direction grid (sampling checks), one mesh of the result for both its volume and membership checks, operand volumes from their meshes, and the intersection tried at the coarser tolerance first (oracle run 10 → 5 minutes); free-form faces merge in the topology counts when their normals agree within 2.5°

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01AS5Tn3xieewUSg3uxrMVdL

crates/geom/src/lib.rs

@@ -11,7 +11,7 @@ mod plane;
 mod profile;
 mod vec;
 
-pub use mesh::{Aabb3, Mesh, MeshMeasure};
+pub use mesh::{Aabb3, InsideIndex, Mesh, MeshMeasure};
 pub use plane::Plane;
 pub use profile::{Loop2, MAX_BEZIER_DEGREE, Region2, Seg2, bezier};
 pub use vec::{Vec2, Vec3};

crates/geom/src/mesh.rs

@@ -227,3 +227,122 @@ impl Mesh {
         best
     }
 }
+
+/// Point-in-mesh queries in bulk: for each of `Mesh::contains`'s three ray directions, the
+/// triangles binned on a grid in the plane square to it, so a ray tests only the triangles
+/// whose shadow covers its cell. Answers exactly as `Mesh::contains` does.
+pub struct InsideIndex<'a> {
+    mesh: &'a Mesh,
+    rays: Vec<RayGrid>,
+}
+
+struct RayGrid {
+    dir: Vec3,
+    u: Vec3,
+    v: Vec3,
+    min: (f64, f64),
+    cell: f64,
+    n: (usize, usize),
+    cells: Vec<Vec<u32>>,
+}
+
+const RAY_DIRS: [Vec3; 3] = [Vec3::new(0.5773, 0.5774, 0.5776), Vec3::new(-0.6123, 0.3141, 0.7254), Vec3::new(0.2718, -0.8414, 0.4673)];
+
+impl Mesh {
+    /// An index for many `contains` queries on this mesh.
+    pub fn inside_index(&self) -> InsideIndex<'_> {
+        let rays = RAY_DIRS
+            .iter()
+            .map(|d| {
+                let u = d.any_perp();
+                let v = d.cross(u);
+                let tris: Vec<[(f64, f64); 3]> = self
+                    .triangles
+                    .iter()
+                    .map(|t| match self.tri(t) {
+                        Some([a, b, c]) => [(a.dot(u), a.dot(v)), (b.dot(u), b.dot(v)), (c.dot(u), c.dot(v))],
+                        None => [(0.0, 0.0); 3],
+                    })
+                    .collect();
+                let (mut lo, mut hi) = ((f64::INFINITY, f64::INFINITY), (f64::NEG_INFINITY, f64::NEG_INFINITY));
+                for t in &tris {
+                    for p in t {
+                        lo = (lo.0.min(p.0), lo.1.min(p.1));
+                        hi = (hi.0.max(p.0), hi.1.max(p.1));
+                    }
+                }
+                let span = (hi.0 - lo.0).max(hi.1 - lo.1).max(1e-9);
+                let side = ((tris.len() as f64).sqrt().ceil() as usize).clamp(1, 256);
+                let cell = span / side as f64 * (1.0 + 1e-9);
+                let n = (side + 1, side + 1);
+                let mut cells = vec![Vec::new(); n.0 * n.1];
+                if lo.0.is_finite() {
+                    for (i, t) in tris.iter().enumerate() {
+                        let (x0, x1) = (t.iter().map(|p| p.0).fold(f64::INFINITY, f64::min), t.iter().map(|p| p.0).fold(f64::NEG_INFINITY, f64::max));
+                        let (y0, y1) = (t.iter().map(|p| p.1).fold(f64::INFINITY, f64::min), t.iter().map(|p| p.1).fold(f64::NEG_INFINITY, f64::max));
+                        let c = |x: f64, o: f64, m: usize| (((x - o) / cell).floor().max(0.0) as usize).min(m - 1);
+                        for gx in c(x0, lo.0, n.0)..=c(x1, lo.0, n.0) {
+                            for gy in c(y0, lo.1, n.1)..=c(y1, lo.1, n.1) {
+                                if let Some(slot) = cells.get_mut(gx * n.1 + gy) {
+                                    slot.push(i as u32);
+                                }
+                            }
+                        }
+                    }
+                }
+                RayGrid { dir: *d, u, v, min: lo, cell, n, cells }
+            })
+            .collect();
+        InsideIndex { mesh: self, rays }
+    }
+}
+
+impl InsideIndex<'_> {
+    fn crossings(&self, g: &RayGrid, o: Vec3) -> usize {
+        let (x, y) = (o.dot(g.u), o.dot(g.v));
+        if !(g.min.0.is_finite()) {
+            return 0;
+        }
+        let (fx, fy) = ((x - g.min.0) / g.cell, (y - g.min.1) / g.cell);
+        if fx < 0.0 || fy < 0.0 {
+            return 0;
+        }
+        let (gx, gy) = (fx.floor() as usize, fy.floor() as usize);
+        if gx >= g.n.0 || gy >= g.n.1 {
+            return 0;
+        }
+        let Some(list) = g.cells.get(gx * g.n.1 + gy) else { return 0 };
+        let dir = g.dir;
+        let mut n = 0;
+        for &i in list {
+            let Some(t) = self.mesh.triangles.get(i as usize) else { continue };
+            let Some([a, b, c]) = self.mesh.tri(t) else { continue };
+            let (e1, e2) = (b - a, c - a);
+            let p = dir.cross(e2);
+            let det = e1.dot(p);
+            if det.abs() < 1e-14 {
+                continue;
+            }
+            let inv = 1.0 / det;
+            let s = o - a;
+            let u = s.dot(p) * inv;
+            if !(0.0..1.0).contains(&u) {
+                continue;
+            }
+            let q = s.cross(e1);
+            let v = dir.dot(q) * inv;
+            if v < 0.0 || u + v >= 1.0 {
+                continue;
+            }
+            if e2.dot(q) * inv > 0.0 {
+                n += 1;
+            }
+        }
+        n
+    }
+
+    /// Same answer as `Mesh::contains`.
+    pub fn contains(&self, p: Vec3) -> bool {
+        self.rays.iter().filter(|g| self.crossings(g, p) % 2 == 1).count() >= 2
+    }
+}

crates/kernel/src/ops.rs

@@ -49,19 +49,20 @@ fn mismatch(a: &solvecraft_geom::Mesh, b: &solvecraft_geom::Mesh, result: &solve
     if lo.x < hi.x && lo.y < hi.y && lo.z < hi.z {
         boxes.push((solvecraft_geom::Aabb3 { min: lo, max: hi }, 900));
     }
+    let (ia_idx, ib_idx, ir_idx) = (a.inside_index(), b.inside_index(), result.inside_index());
     let (mut n, mut bad) = (0usize, 0usize);
     for (bx, count) in boxes {
         let s = bx.size();
         for i in 1..=count {
             let p = bx.min + Vec3::new(s.x * halton(i, 2), s.y * halton(i, 3), s.z * halton(i, 5));
-            let (ia, ib) = (a.contains(p), b.contains(p));
+            let (ia, ib) = (ia_idx.contains(p), ib_idx.contains(p));
             let want = match op {
                 BoolOp::Union => ia || ib,
                 BoolOp::Cut => ia && !ib,
                 BoolOp::Intersect => ia && ib,
             };
             n += 1;
-            if result.contains(p) != want {
+            if ir_idx.contains(p) != want {
                 bad += 1;
             }
         }
@@ -75,23 +76,24 @@ fn overlap(a: &solvecraft_geom::Mesh, b: &solvecraft_geom::Mesh) -> Option<(f64,
     if a.triangles.len() + b.triangles.len() > 80_000 {
         return None;
     }
-    let frac = |inner: &solvecraft_geom::Mesh, outer: &solvecraft_geom::Mesh| -> Option<f64> {
+    let (ia, ib) = (a.inside_index(), b.inside_index());
+    let frac = |inner: &solvecraft_geom::Mesh, inner_i: &solvecraft_geom::InsideIndex, outer_i: &solvecraft_geom::InsideIndex| -> Option<f64> {
         let bx = inner.bounds();
         let s = bx.size();
         let (mut n, mut hit) = (0usize, 0usize);
         for i in 1..=2000 {
             let p = bx.min + Vec3::new(s.x * halton(i, 2), s.y * halton(i, 3), s.z * halton(i, 5));
-            if !inner.contains(p) {
+            if !inner_i.contains(p) {
                 continue;
             }
             n += 1;
-            if outer.contains(p) {
+            if outer_i.contains(p) {
                 hit += 1;
             }
         }
         (n >= 50).then(|| hit as f64 / n as f64)
     };
-    Some((frac(b, a)?, frac(a, b)?))
+    Some((frac(b, &ib, &ia)?, frac(a, &ia, &ib)?))
 }
 
 /// Booleans that need no intersection: one body clear of the other, or inside it. These are
@@ -163,22 +165,32 @@ pub fn boolean(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
     a.require_brep("a boolean")?;
     b.require_brep("a boolean")?;
     let size = a.size().max(b.size());
-    let (va, vb) = (volume(a), volume(b));
-    let slack = 2e-3 * (va + vb) + 1e-9;
     let tol_m = size * 5e-4;
     let meshes = (a.tessellate(tol_m).ok(), b.tessellate(tol_m).ok());
-    let plausible = |v: f64, r: &Body| {
-        let bounds = match op {
-            BoolOp::Union => v >= va.max(vb) - slack && v <= va + vb + slack,
-            BoolOp::Cut => v >= va - vb - slack && v <= va + slack,
-            BoolOp::Intersect => v <= va.min(vb) + slack,
-        };
-        // Membership check against the operands (catches misclassified pieces).
-        let consistent = match (&meshes, r.tessellate(tol_m)) {
-            ((Some(ma), Some(mb)), Ok(mr)) => mismatch(ma, mb, &mr, op).is_none_or(|f| f < 0.004),
+    let (va, vb) = match &meshes {
+        (Some(ma), Some(mb)) => (ma.measure().volume, mb.measure().volume),
+        _ => (volume(a), volume(b)),
+    };
+    let slack = 2e-3 * (va + vb) + 1e-9;
+    // Volume bounds, then membership against the operands (catches misclassified pieces), on
+    // one mesh of the result. Returns (plausible, volume).
+    let check = |r: &Body| -> (bool, f64) {
+        let Ok(mr) = r.tessellate(tol_m) else { return (false, f64::NAN) };
+        let v = mr.measure().volume;
+        let bounds = v > 0.0
+            && match op {
+                BoolOp::Union => v >= va.max(vb) - slack && v <= va + vb + slack,
+                BoolOp::Cut => v >= va - vb - slack && v <= va + slack,
+                BoolOp::Intersect => v <= va.min(vb) + slack,
+            };
+        if !bounds {
+            return (false, v);
+        }
+        let consistent = match &meshes {
+            (Some(ma), Some(mb)) => mismatch(ma, mb, &mr, op).is_none_or(|f| f < 0.004),
             _ => true,
         };
-        bounds && consistent
+        (consistent, v)
     };
     // One body clear of or inside the other: no intersection needed.
     if let (Some(ma), Some(mb)) = &meshes
@@ -212,8 +224,8 @@ pub fn boolean(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
         && b.solid.boundaries().len() == 1
         && let Some(Ok(body)) = crate::coplanar::glue(a, b)
     {
-        let v = volume(&body);
-        if v > 0.0 && plausible(v, &body) {
+        let (ok, _) = check(&body);
+        if ok {
             return Ok(Some(body));
         }
     }
@@ -222,8 +234,8 @@ pub fn boolean(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
         let r = crate::coplanar::boolean_apart(a, b, op);
         APART.with(|c| c.set(false));
         if let Some(Ok(Some(body))) = r {
-            let v = volume(&body);
-            if v > 0.0 && plausible(v, &body) {
+            let (ok, _) = check(&body);
+            if ok {
                 return Ok(Some(body));
             }
         }
@@ -231,7 +243,7 @@ pub fn boolean(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
     let mut empty_votes = 0;
     for (attempt, j) in JITTER.iter().enumerate() {
         let shift = mt::Vector3::new(j[0], j[1], j[2]) * (size * 0.01);
-        for k in [5e-4, 2e-3] {
+        for k in [2e-3, 5e-4] {
             let tol = (size * k).max(1e-5);
             let r = guard("boolean", || {
                 let (mut sa, mut sb) = (a.deep_copy(), b.deep_copy());
@@ -257,8 +269,8 @@ pub fn boolean(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
                 }
                 Ok(s) => match Body::new(crate::heal::heal(s, size)) {
                     Ok(body) => {
-                        let v = volume(&body);
-                        if v > 0.0 && plausible(v, &body) {
+                        let (ok, v) = check(&body);
+                        if ok {
                             return Ok(Some(body));
                         }
                         last = format!("implausible result volume {v:.4}");
@@ -279,8 +291,8 @@ pub fn boolean(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
         APART.with(|c| c.set(false));
         match r {
             Some(Ok(Some(body))) => {
-                let v = volume(&body);
-                if v > 0.0 && plausible(v, &body) {
+                let (ok, v) = check(&body);
+                if ok {
                     return Ok(Some(body));
                 }
                 last = format!("{last}; faces pushed apart gave an implausible volume {v:.4}");
@@ -294,8 +306,8 @@ pub fn boolean(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
     // polygon fallback.
     match crate::polybool::planar_boolean(a, b, op) {
         Ok(Some(body)) => {
-            let v = volume(&body);
-            if v > 0.0 && plausible(v, &body) {
+            let (ok, v) = check(&body);
+            if ok {
                 return Ok(Some(body));
             }
             last = format!("planar fallback gave an implausible volume {v:.4}");
@@ -313,8 +325,8 @@ pub fn boolean(a: &Body, b: &Body, op: BoolOp) -> Result<Option<Body>> {
         APART.with(|c| c.set(false));
         match r {
             Ok(Some(body)) => {
-                let v = volume(&body);
-                if v > 0.0 && plausible(v, &body) {
+                let (ok, v) = check(&body);
+                if ok {
                     return Ok(Some(body));
                 }
                 last = format!("{last}; the nudged tool gave an implausible volume {v:.4}");

crates/kernel/src/topo.rs

@@ -411,7 +411,7 @@ pub fn merged_topology(b: &Body, mesh: &Mesh) -> Result<TopoCounts> {
             match (sa.search_nearest_parameter(q, None, 50), sb.search_nearest_parameter(q, None, 50)) {
                 (Some((u, v)), Some((s, t))) => {
                     let (x, y) = (sa.normal(u, v), sb.normal(s, t));
-                    x.x * y.x + x.y * y.y + x.z * y.z > 1.0 - 1e-4
+                    x.x * y.x + x.y * y.y + x.z * y.z > 1.0 - 1e-3
                 }
                 _ => false,
             }