@faicad/sheetmetal 0.16.1 → 0.18.0

package/dist/unfoldFns.js.map

@@ -1 +1 @@
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{\n  type Result,\n  type Wire,\n  type Edge,\n  ok,\n  err,\n  validationError,\n  line,\n  wire,\n  wireLoop,\n} from '@faicad/faijs/brepjs-compat';\nimport type {\n  SheetMetalPart,\n  UnfoldResult,\n  FlatPattern,\n  BendReport,\n  SheetMetalWarning,\n  CornerMiter,\n  FlatSide,\n} from './types.js';\nimport { featureTree, type FeatureTree, ROOT_FLAT_ID } from './featureTreeFns.js';\nimport { developedLength } from './allowanceFns.js';\nimport { sideFromAxisDir } from './internal.js';\n\ntype Pt2 = [number, number];\n\n/**\n * Tree-driven analytic unfold of an arbitrary straight-bend part into its flat\n * pattern. Walks the feature tree in BFS order placing every flat in the flat\n * plane: the base occupies `[0,baseLength]×[0,width]`; each child flange lays a\n * developed-bend strip (width = neutral-axis arc length) along the parent edge it\n * folds from — respecting its offset/span along that edge — then its own flat past\n * the strip, perpendicular to the edge and pointing outward. The developed outline\n * is the rectilinear union of the base and every placed flat/strip rectangle,\n * emitted as a single closed morph wire. A recorded corner miter replaces the\n * shared reflex corner of two perpendicular base flanges with a 45° chamfer.\n * Closed profiles produce a SEAM_CUT warning (the cycle-closing bend is left\n * unfolded). Warnings ride inside the Ok payload.\n *\n * @param part - the sheet-metal part to develop into its flat pattern\n * @returns the flat pattern (outline, bend lines, holes, form cuts/markers/hinges,\n *   lofted developments, developed area), the bend report, and any warnings — or\n *   an error if the part cannot be unfolded\n */\nexport function unfold(part: SheetMetalPart): Result<UnfoldResult> {\n  const treeResult = featureTree(part);\n  if (!treeResult.ok) return treeResult;\n  const tree = treeResult.value;\n\n  const baseLength = part.baseLength;\n  if (!Number.isFinite(baseLength) || baseLength <= 0) {\n    return err(validationError('INVALID_BASE_LENGTH', `part baseLength must be positive, got ${baseLength}`));\n  }\n  const width = part.width;\n  if (!Number.isFinite(width) || width <= 0) {\n    return err(validationError('INVALID_WIDTH', `part width must be positive, got ${width}`));\n  }\n\n  const warnings: SheetMetalWarning[] = [...tree.warnings];\n\n  const layoutResult = layoutTree(part, tree, baseLength, width, (warning) => warnings.push(warning));\n  if (!layoutResult.ok) return layoutResult;\n  const layout = layoutResult.value;\n\n  for (const placed of layout.flats) {\n    if (placed.kind !== 'flange') continue;\n    if (part.thickness > 0 && placed.rule.innerRadius < part.thickness) {\n      warnings.push({\n        code: 'MIN_RADIUS',\n        message: `bend '${placed.id}' inner radius ${placed.rule.innerRadius} < thickness ${part.thickness}`,\n        featureId: placed.id,\n      });\n    }\n  }\n\n  // Contour-flange developed strips lay out straight along their base edge; compute\n  // them first so their rectangles join the outline union below.\n  const contourResult = buildContourDevelopments(part);\n  if (!contourResult.ok) return contourResult;\n\n  // Hems and jogs lay their multi-bend developed strips out straight along their\n  // region edge (the base or a flange), exactly like a contour flange.\n  const hemJogResult = buildHemJogDevelopments(part, layout);\n  if (!hemJogResult.ok) return hemJogResult;\n\n  const rects: Rect[] = [];\n  for (const placed of layout.flats) rects.push(placed.rect);\n  for (const strip of layout.strips) rects.push(strip);\n  for (const strip of contourResult.value.strips) rects.push(strip);\n  for (const strip of hemJogResult.value.strips) rects.push(strip);\n\n  // Tabs are additive protrusions: their developed rectangles join the outer-outline\n  // union and add to the developed area.\n  const tabRects: Rect[] = (part.tabs ?? []).map((t) => ({ x0: t.rect[0], y0: t.rect[1], x1: t.rect[2], y1: t.rect[3] }));\n  for (const r of tabRects) rects.push(r);\n\n  const notches: Rect[] = (part.reliefs ?? []).flatMap((relief) =>\n    relief.notches.map(([x0, y0, x1, y1]) => ({ x0, y0, x1, y1 }))\n  );\n  // The L-miter chamfer special-case can't express tabs either; once any tab is\n  // recorded, fall through to the rectilinear-union path (which absorbs tab rects).\n  // The 3D corner-miter cut still stands; only the developed chamfer is omitted.\n  const miters = tabRects.length > 0 ? [] : part.miters ?? [];\n  if (tabRects.length > 0 && (part.miters ?? []).length > 0) {\n    warnings.push({\n      code: 'MITER_NOT_DEVELOPED',\n      message: 'developed outline omits the corner-miter chamfer because a tab is present; the 3D miter cut is unaffected',\n    });\n  }\n  const outlineResult = buildOutline(rects, layout, miters, notches);\n  if (!outlineResult.ok) return outlineResult;\n  layout.developedArea -= removedNotchArea(rects, notches);\n  for (const t of part.tabs ?? []) layout.developedArea += t.area;\n\n  const holesResult = buildHoles(part);\n  if (!holesResult.ok) return holesResult;\n  for (const c of part.cutouts ?? []) layout.developedArea -= c.area;\n\n  const formsResult = buildForms(part);\n  if (!formsResult.ok) return formsResult;\n\n  const loftedResult = buildLoftedDevelopments(part);\n  if (!loftedResult.ok) return loftedResult;\n  for (const lf of part.loftedFlanges ?? []) {\n    layout.developedArea += lf.developedArea;\n    if (lf.approximate) {\n      warnings.push({\n        code: 'DEVELOPMENT_APPROXIMATE',\n        message: `lofted flange '${lf.id}' transition is not developable; its triangulated flat development is an approximation`,\n        featureId: lf.id,\n      });\n    }\n  }\n\n  for (const cf of part.contourFlanges ?? []) {\n    layout.developedArea += cf.developedLength * cf.span;\n  }\n\n  for (const h of part.hems ?? []) {\n    layout.developedArea += h.developedLength * h.span;\n  }\n  for (const j of part.jogs ?? []) {\n    layout.developedArea += j.developedLength * j.span;\n  }\n\n  const bendLines = layout.flats\n    .filter((p): p is PlacedFlange => p.kind === 'flange')\n    .map((p) => ({\n      id: p.id,\n      line: bendLineEdge(p),\n      angleDeg: p.angleDeg,\n      direction: p.direction,\n      // The child frame's v axis is the develop-out direction; into-parent is its\n      // negation. Correct for chained flanges too (it is local to the placement).\n      inward: [-p.frame.v[0], -p.frame.v[1]] as [number, number],\n    }))\n    .concat(contourResult.value.bendLines)\n    .concat(hemJogResult.value.bendLines);\n\n  const pattern: FlatPattern = {\n    outline: outlineResult.value,\n    bendLines,\n    holes: holesResult.value,\n    formCuts: formsResult.value.cuts,\n    formMarkers: formsResult.value.markers,\n    formHinges: formsResult.value.hinges,\n    loftedDevelopments: loftedResult.value,\n    developedArea: layout.developedArea,\n  };\n\n  const report = reportFromLayout(layout);\n\n  return ok({ pattern, report, warnings });\n}\n\n/** A placed flat rectangle in the developed (flat-pattern) plane. */\nexport interface Rect {\n  x0: number;\n  y0: number;\n  x1: number;\n  y1: number;\n}\n\n/** 2D frame of a placed flat: occupies [0,uLen]×[0,vLen] in (u,v) from `origin`. */\nexport interface Frame2 {\n  origin: Pt2;\n  u: Pt2;\n  v: Pt2;\n  uLen: number;\n  vLen: number;\n}\n\n/** A placed base flat: the root rectangle `[0,baseLength]×[0,width]`. */\nexport interface PlacedBase {\n  kind: 'base';\n  id: string;\n  rect: Rect;\n  frame: Frame2;\n}\n\n/** A placed flange flat: a developed strip laid along a parent edge plus its own flat. */\nexport interface PlacedFlange {\n  kind: 'flange';\n  id: string;\n  rect: Rect;\n  frame: Frame2;\n  /** Strip rectangle laid along the parent edge (developed bend). */\n  strip: Rect;\n  /** Bend line endpoints (along the parent edge, over the flange span). */\n  bendA: Pt2;\n  bendB: Pt2;\n  dev: number;\n  length: number;\n  span: number;\n  angleDeg: number;\n  direction: 'up' | 'down';\n  rule: { innerRadius: number; kFactor: number; allowance?: number | undefined };\n  /** True when this flange folds directly off the base and spans its full edge. */\n  baseFull: boolean;\n  side: FlatSide;\n}\n\n/** A placed flat in the developed plane: either the base or a flange. */\nexport type Placed = PlacedBase | PlacedFlange;\n\n/** The result of {@link layoutTree}: developed dimensions, placed flats, and strips. */\nexport interface TreeLayout {\n  baseLength: number;\n  width: number;\n  developedArea: number;\n  flats: Placed[];\n  strips: Rect[];\n}\n\n/**\n * Lay out the feature tree's flats in the flat plane, starting from the base and\n * placing each bend's child flange along its parent edge: a developed strip laid\n * outward from the edge, then the child's own flat. Produces the placed flats,\n * their strips, and the total developed area.\n *\n * @param part - the sheet-metal part whose features are laid out\n * @param tree - the feature tree built from the part\n * @param baseLength - length of the base flat (u extent)\n * @param width - width of the base flat (v extent)\n * @param onWarning - optional callback invoked for warnings raised while unfolding\n * @returns the laid-out flats, strips, and developed area, or an error if a\n *   referenced flat has no flange feature or is missing from the layout\n */\nexport function layoutTree(\n  part: SheetMetalPart,\n  tree: FeatureTree,\n  baseLength: number,\n  width: number,\n  onWarning?: (warning: SheetMetalWarning) => void\n): Result<TreeLayout> {\n  const frames = new Map<string, Frame2>();\n  frames.set(ROOT_FLAT_ID, {\n    origin: [0, 0],\n    u: [1, 0],\n    v: [0, 1],\n    uLen: baseLength,\n    vLen: width,\n  });\n\n  const flats: Placed[] = [\n    {\n      kind: 'base',\n      id: ROOT_FLAT_ID,\n      frame: frames.get(ROOT_FLAT_ID) as Frame2,\n      rect: rectOf(frames.get(ROOT_FLAT_ID) as Frame2),\n    },\n  ];\n  const strips: Rect[] = [];\n  let developedArea = baseLength * width;\n\n  for (const treeBend of tree.bends) {\n    const childNode = tree.nodes.get(treeBend.child);\n    if (childNode === undefined || childNode.flange === undefined) {\n      return err(\n        validationError('UNKNOWN_FLAT', `child flat '${treeBend.child}' has no flange feature`)\n      );\n    }\n    const flange = childNode.flange;\n    const parentFrame = frames.get(treeBend.parent);\n    if (parentFrame === undefined) {\n      return err(\n        validationError('UNKNOWN_FLAT', `parent flat '${treeBend.parent}' missing from layout`)\n      );\n    }\n\n    const devResult = developedLength(treeBend.bend.angleDeg, part.thickness, treeBend.bend.rule, onWarning);\n    if (!devResult.ok) return devResult;\n    const dev = devResult.value;\n\n    // Authored parts always record `baseEdge.side`; hand-built fixtures may encode\n    // the develop direction only via the bend axis, so fall back to that.\n    const side: FlatSide = flange.baseEdge.side ?? sideFromAxisDir(treeBend.bend.axisDir) ?? 'xmax';\n    const offset = flange.offset ?? flange.baseEdge.offset ?? 0;\n    const span = flange.span;\n    const length = flange.length;\n\n    const placed = placeChild(flange.id, parentFrame, side, offset, span, dev, length, {\n      angleDeg: treeBend.bend.angleDeg,\n      direction: treeBend.bend.direction,\n      rule: treeBend.bend.rule,\n      baseFull: treeBend.parent === ROOT_FLAT_ID && offset <= 1e-6 && span >= edgeLength(parentFrame, side) - 1e-6,\n      side,\n    });\n    frames.set(flange.id, placed.frame);\n    flats.push(placed);\n    strips.push(placed.strip);\n    developedArea += (dev + length) * span;\n  }\n\n  return ok({ baseLength, width, developedArea, flats, strips });\n}\n\nfunction edgeLength(f: Frame2, side: FlatSide): number {\n  return side === 'xmax' || side === 'xmin' ? f.vLen : f.uLen;\n}\n\n/**\n * Place a child flange off `parent`'s edge `side`. The strip (developed bend) is\n * laid from the edge outward by `dev`; the child flat follows for `length`. The\n * child's own 2D frame starts past the strip so grandchildren chain correctly.\n */\nfunction placeChild(\n  id: string,\n  parent: Frame2,\n  side: FlatSide,\n  offset: number,\n  span: number,\n  dev: number,\n  length: number,\n  meta: {\n    angleDeg: number;\n    direction: 'up' | 'down';\n    rule: { innerRadius: number; kFactor: number; allowance?: number | undefined };\n    baseFull: boolean;\n    side: FlatSide;\n  }\n): PlacedFlange {\n  // Edge basis in 2D: `along` runs the edge (bend axis), `out` points outward.\n  const { along, out, edgeOrigin } = edgeBasis2(parent, side);\n\n  const base = add2(edgeOrigin, scale2(along, offset));\n  const bendA = base;\n  const bendB = add2(base, scale2(along, span));\n\n  const stripFar = add2(base, scale2(out, dev));\n\n  const strip = rectFromCorners(base, add2(bendB, scale2(out, dev)));\n  const flatRect = rectFromCorners(stripFar, add2(add2(stripFar, scale2(along, span)), scale2(out, length)));\n\n  const childFrame: Frame2 = {\n    origin: stripFar,\n    u: along,\n    v: out,\n    uLen: span,\n    vLen: length,\n  };\n\n  return {\n    kind: 'flange',\n    id,\n    frame: childFrame,\n    rect: flatRect,\n    strip,\n    bendA,\n    bendB,\n    dev,\n    length,\n    span,\n    angleDeg: meta.angleDeg,\n    direction: meta.direction,\n    rule: meta.rule,\n    baseFull: meta.baseFull,\n    side: meta.side,\n  };\n}\n\n/**\n * Edge origin and along/out unit directions for one side of a 2D frame. `along`\n * runs along the edge (the bend axis), `out` points outward from the frame, and\n * `edgeOrigin` is the starting corner of that edge.\n *\n * @param f - the 2D frame whose edge basis is computed\n * @param side - which side of the frame ('xmax' | 'xmin' | 'ymax' | 'ymin')\n * @returns the along/out unit directions and the edge's origin corner\n */\nexport function edgeBasis2(f: Frame2, side: FlatSide): { along: Pt2; out: Pt2; edgeOrigin: Pt2 } {\n  const uTop = add2(f.origin, scale2(f.u, f.uLen));\n  const vTop = add2(f.origin, scale2(f.v, f.vLen));\n  switch (side) {\n    case 'xmax':\n      return { along: f.v, out: f.u, edgeOrigin: uTop };\n    case 'xmin':\n      return { along: f.v, out: neg2(f.u), edgeOrigin: f.origin };\n    case 'ymax':\n      return { along: f.u, out: f.v, edgeOrigin: vTop };\n    case 'ymin':\n      return { along: f.u, out: neg2(f.v), edgeOrigin: f.origin };\n    default:\n      return side satisfies never;\n  }\n}\n\nfunction bendLineEdge(p: PlacedFlange): Edge {\n  return line([p.bendA[0], p.bendA[1], 0], [p.bendB[0], p.bendB[1], 0]);\n}\n\n/**\n * One closed developed-plane {@link Wire} per recorded cutout, traced from the\n * feature's already-mapped `loop` (which {@link addCutout} positioned via the\n * region's developed frame, so the loop sits at the cutout's matching flat-pattern\n * spot). Emitted as interior holes of the pattern; the outer outline is unchanged.\n */\nfunction buildHoles(part: SheetMetalPart): Result<Wire[]> {\n  const wires: Wire[] = [];\n  for (const c of part.cutouts ?? []) {\n    const loop = c.loop;\n    if (loop.length < 3) {\n      return err(validationError('CUTOUT_LOOP_TOO_SMALL', `cutout loop has ${loop.length} points, need ≥ 3`));\n    }\n    const edges: Edge[] = [];\n    for (let i = 0; i < loop.length; i += 1) {\n      const a = loop[i];\n      const b = loop[(i + 1) % loop.length];\n      if (a === undefined || b === undefined) {\n        return err(validationError('CUTOUT_LOOP_FAILED', 'failed to index cutout loop'));\n      }\n      edges.push(line([a[0], a[1], 0], [b[0], b[1], 0]));\n    }\n    const wire = wireLoop(edges);\n    if (!wire.ok) return wire;\n    wires.push(wire.value);\n  }\n  return ok(wires);\n}\n\ninterface FormWires {\n  cuts: Wire[];\n  markers: Wire[];\n  hinges: Edge[];\n}\n\n/**\n * Developed-plane wires for recorded form features: each louver U-cut and emboss\n * footprint as a closed {@link Wire}, plus each louver hinge as an {@link Edge}. The\n * loops were already mapped into developed coordinates when the form was recorded\n * (via the region's developed frame), so this just traces them. Forms are net-\n * material-neutral, so the outer outline and developed area are untouched.\n */\nfunction buildForms(part: SheetMetalPart): Result<FormWires> {\n  const cuts: Wire[] = [];\n  const markers: Wire[] = [];\n  const hinges: Edge[] = [];\n  for (const form of part.forms ?? []) {\n    for (const path of form.cuts) {\n      const cutWire = openPathWire(path);\n      if (!cutWire.ok) return cutWire;\n      cuts.push(cutWire.value);\n    }\n    for (const loop of form.markers) {\n      const markerWire = closedLoopWire(loop);\n      if (!markerWire.ok) return markerWire;\n      markers.push(markerWire.value);\n    }\n    if (form.hinge !== undefined) {\n      const [a, b] = form.hinge;\n      hinges.push(line([a[0], a[1], 0], [b[0], b[1], 0]));\n    }\n  }\n  return ok({ cuts, markers, hinges });\n}\n\n/**\n * Closed developed-plane {@link Wire}s for recorded lofted/ruled transition flanges.\n * Each feature's triangulated `developedLoop` was already laid out flat when the\n * flange was authored, so this just traces it into a wire; the boundary is non-\n * rectilinear so it rides separately from the rectilinear-union outline.\n */\nfunction buildLoftedDevelopments(part: SheetMetalPart): Result<Wire[]> {\n  const wires: Wire[] = [];\n  for (const lf of part.loftedFlanges ?? []) {\n    const w = closedLoopWire(lf.developedLoop);\n    if (!w.ok) return w;\n    wires.push(w.value);\n  }\n  return ok(wires);\n}\n\ninterface ContourDevelopments {\n  /** Developed strip rectangles (one per contour flange) for the outline union. */\n  strips: Rect[];\n  /** Developed bend lines (one per arc segment) in the flat pattern. */\n  bendLines: FlatPattern['bendLines'];\n}\n\n/**\n * Lay each recorded contour flange's developed strip out STRAIGHT along its base\n * edge: a rectangle `span` wide along the edge by `developedLength` out from it,\n * returned for the outer-outline union. One bend line per arc segment is placed at\n * that segment's cumulative developed offset out from the base edge — the EXACT\n * arc-length sum, so the strip length equals Σ segment developed lengths with no\n * error.\n */\nfunction buildContourDevelopments(part: SheetMetalPart): Result<ContourDevelopments> {\n  const strips: Rect[] = [];\n  const bendLines: FlatPattern['bendLines'] = [];\n  const baseFrame: Frame2 = {\n    origin: [0, 0],\n    u: [1, 0],\n    v: [0, 1],\n    uLen: part.baseLength,\n    vLen: part.width,\n  };\n\n  for (const cf of part.contourFlanges ?? []) {\n    const { along, out, edgeOrigin } = edgeBasis2(baseFrame, cf.side);\n    const base = add2(edgeOrigin, scale2(along, cf.offset));\n    strips.push(\n      rectFromCorners(base, add2(add2(base, scale2(along, cf.span)), scale2(out, cf.developedLength)))\n    );\n\n    let cumulative = 0;\n    for (const seg of cf.segments) {\n      if (seg.kind === 'arc') {\n        const a = add2(base, scale2(out, cumulative));\n        const b = add2(a, scale2(along, cf.span));\n        bendLines.push({\n          id: seg.bendId ?? cf.id,\n          line: line([a[0], a[1], 0], [b[0], b[1], 0]),\n          angleDeg: seg.angleDeg ?? 0,\n          direction: seg.direction ?? 'up',\n          inward: [-out[0], -out[1]] as [number, number],\n        });\n      }\n      cumulative += seg.dev;\n    }\n  }\n  return ok({ strips, bendLines });\n}\n\ninterface HemJogDevelopments {\n  /** Developed strip rectangles (one per hem/jog) for the outline union. */\n  strips: Rect[];\n  /** Developed bend lines (one per curl/step sub-bend) in the flat pattern. */\n  bendLines: FlatPattern['bendLines'];\n}\n\n/**\n * Lay each recorded hem and jog developed strip out STRAIGHT along its region edge\n * (the base or a flange), mirroring {@link buildContourDevelopments}. The region's\n * developed-plane {@link Frame2} comes from the tree layout (so a hem on a flange\n * lands on that flange's developed face). Each sub-bend (a hem curl arc or a jog\n * step arc) gets a bend line at its EXACT cumulative developed offset out from the\n * edge — Σ segment developed lengths, so the strip length is exact.\n */\nfunction buildHemJogDevelopments(part: SheetMetalPart, layout: TreeLayout): Result<HemJogDevelopments> {\n  const strips: Rect[] = [];\n  const bendLines: FlatPattern['bendLines'] = [];\n\n  const frameFor = (region: string): Frame2 | undefined => {\n    const id = region === 'base' || region === 'face-0' ? ROOT_FLAT_ID : region;\n    for (const p of layout.flats) {\n      if (p.id === id) return p.frame;\n    }\n    return undefined;\n  };\n\n  interface Strip {\n    region: string;\n    side: FlatSide;\n    offset: number;\n    span: number;\n    developedLength: number;\n    segments: {\n      kind: 'line' | 'arc';\n      dev: number;\n      angleDeg?: number | undefined;\n      direction?: 'up' | 'down' | undefined;\n      bendId?: string | undefined;\n    }[];\n  }\n  const allStrips: Strip[] = [\n    ...(part.hems ?? []).map((h) => ({\n      region: h.region,\n      side: h.side,\n      offset: h.offset,\n      span: h.span,\n      developedLength: h.developedLength,\n      segments: h.segments,\n    })),\n    ...(part.jogs ?? []).map((j) => ({\n      region: j.region,\n      side: j.side,\n      offset: j.offset,\n      span: j.span,\n      developedLength: j.developedLength,\n      segments: j.segments,\n    })),\n  ];\n\n  for (const s of allStrips) {\n    const regionFrame = frameFor(s.region);\n    if (regionFrame === undefined) {\n      return err(validationError('UNKNOWN_HEMJOG_REGION', `hem/jog region '${s.region}' missing from layout`));\n    }\n    const { along, out, edgeOrigin } = edgeBasis2(regionFrame, s.side);\n    const base = add2(edgeOrigin, scale2(along, s.offset));\n    strips.push(rectFromCorners(base, add2(add2(base, scale2(along, s.span)), scale2(out, s.developedLength))));\n\n    let cumulative = 0;\n    for (const seg of s.segments) {\n      if (seg.kind === 'arc') {\n        const a = add2(base, scale2(out, cumulative));\n        const b = add2(a, scale2(along, s.span));\n        bendLines.push({\n          id: seg.bendId ?? s.region,\n          line: line([a[0], a[1], 0], [b[0], b[1], 0]),\n          angleDeg: seg.angleDeg ?? 0,\n          direction: seg.direction ?? 'up',\n          inward: [-out[0], -out[1]] as [number, number],\n        });\n      }\n      cumulative += seg.dev;\n    }\n  }\n  return ok({ strips, bendLines });\n}\n\n/** Trace a closed developed-plane loop (≥ 3 points) into a morph {@link Wire}. */\nfunction closedLoopWire(loop: Pt2[]): Result<Wire> {\n  if (loop.length < 3) {\n    return err(validationError('FORM_LOOP_TOO_SMALL', `form loop has ${loop.length} points, need ≥ 3`));\n  }\n  const edges: Edge[] = [];\n  for (let i = 0; i < loop.length; i += 1) {\n    const a = loop[i];\n    const b = loop[(i + 1) % loop.length];\n    if (a === undefined || b === undefined) {\n      return err(validationError('FORM_LOOP_FAILED', 'failed to index form loop'));\n    }\n    edges.push(line([a[0], a[1], 0], [b[0], b[1], 0]));\n  }\n  return wireLoop(edges);\n}\n\n/** Trace an OPEN developed-plane path (≥ 2 points) into a morph {@link Wire}. */\nfunction openPathWire(path: Pt2[]): Result<Wire> {\n  if (path.length < 2) {\n    return err(validationError('FORM_PATH_TOO_SHORT', `form cut path has ${path.length} points, need ≥ 2`));\n  }\n  const edges: Edge[] = [];\n  for (let i = 0; i + 1 < path.length; i += 1) {\n    const a = path[i];\n    const b = path[i + 1];\n    if (a === undefined || b === undefined) {\n      return err(validationError('FORM_LOOP_FAILED', 'failed to index form cut path'));\n    }\n    edges.push(line([a[0], a[1], 0], [b[0], b[1], 0]));\n  }\n  return wire(edges);\n}\n\nfunction rectOf(f: Frame2): Rect {\n  const c0 = f.origin;\n  const c1 = add2(add2(f.origin, scale2(f.u, f.uLen)), scale2(f.v, f.vLen));\n  return rectFromCorners(c0, c1);\n}\n\nfunction rectFromCorners(a: Pt2, b: Pt2): Rect {\n  return {\n    x0: Math.min(a[0], b[0]),\n    y0: Math.min(a[1], b[1]),\n    x1: Math.max(a[0], b[0]),\n    y1: Math.max(a[1], b[1]),\n  };\n}\n\nfunction add2(a: Pt2, b: Pt2): Pt2 {\n  return [a[0] + b[0], a[1] + b[1]];\n}\nfunction scale2(a: Pt2, s: number): Pt2 {\n  return [a[0] * s, a[1] * s];\n}\nfunction neg2(a: Pt2): Pt2 {\n  return [-a[0], -a[1]];\n}\n\n/**\n * Outline of the developed pattern. For the simple two-perpendicular-flange L\n * (base + an east + a north flange) a recorded corner miter chamfers the reflex\n * vertex; otherwise the outline is the rectilinear union of all placed rectangles\n * emitted as one closed loop. Holes are not possible for the supported shapes\n * (every arm attaches to the simply-connected base or a chain thereof).\n */\nfunction buildOutline(\n  rects: Rect[],\n  layout: TreeLayout,\n  miters: CornerMiter[],\n  notches: Rect[]\n): Result<Wire> {\n  // The lShapedMiter chamfer special-case can't express a notch, so once any relief\n  // is recorded fall through to the rectilinear-union path (which subtracts notches).\n  const miterCorners = notches.length > 0 ? undefined : lShapedMiter(layout, miters);\n  const corners = miterCorners ?? rectilinearUnion(rects, notches);\n  if (corners.length < 3) {\n    return err(validationError('OUTLINE_BUILD_FAILED', 'developed outline has fewer than 3 vertices'));\n  }\n  const edges: Edge[] = [];\n  for (let i = 0; i < corners.length; i += 1) {\n    const from = corners[i];\n    const to = corners[(i + 1) % corners.length];\n    if (from === undefined || to === undefined) {\n      return err(validationError('OUTLINE_BUILD_FAILED', 'failed to index outline corners'));\n    }\n    edges.push(line([from[0], from[1], 0], [to[0], to[1], 0]));\n  }\n  return wireLoop(edges);\n}\n\n/**\n * Special-case the classic L: a base with exactly one east (+X) and one north\n * (+Y) full-span flange and a recorded miter between them. Returns the chamfered\n * hexagon; `undefined` if this isn't that shape (fall back to the union outline).\n */\nfunction lShapedMiter(layout: TreeLayout, miters: CornerMiter[]): Pt2[] | undefined {\n  const flanges = layout.flats.filter((p): p is PlacedFlange => p.kind === 'flange');\n  if (flanges.length !== 2) return undefined;\n  const east = flanges.find((f) => f.baseFull && f.side === 'xmax');\n  const north = flanges.find((f) => f.baseFull && f.side === 'ymax');\n  if (east === undefined || north === undefined) return undefined;\n\n  const baseLength = layout.baseLength;\n  const width = layout.width;\n  const maxX = baseLength + east.dev + east.length;\n  const maxY = width + north.dev + north.length;\n  const gap = miterGapFor(miters, east.id, north.id);\n\n  if (gap === undefined || gap <= 0) {\n    return [\n      [0, 0],\n      [maxX, 0],\n      [maxX, width],\n      [baseLength, width],\n      [baseLength, maxY],\n      [0, maxY],\n    ];\n  }\n  return [\n    [0, 0],\n    [maxX, 0],\n    [maxX, width],\n    [baseLength + gap, width],\n    [baseLength, width + gap],\n    [baseLength, maxY],\n    [0, maxY],\n  ];\n}\n\nfunction miterGapFor(miters: CornerMiter[], aId: string, bId: string): number | undefined {\n  for (const m of miters) {\n    if ((m.flangeA === aId && m.flangeB === bId) || (m.flangeA === bId && m.flangeB === aId)) {\n      return m.gap;\n    }\n  }\n  return undefined;\n}\n\n/**\n * Outline loop of the union of axis-aligned rectangles, assuming the union is a\n * single simply-connected rectilinear region (true for every shape this package\n * authors: arms attached to a connected base). Built by a vertical-line sweep\n * tracking the covered y-spans, then tracing the boundary contour. The sweep emits\n * a CCW loop of corner points with no collinear duplicates.\n */\nfunction rectilinearUnion(rects: Rect[], notches: Rect[] = []): Pt2[] {\n  const cuts = [...rects.flatMap((r) => [r.x0, r.x1]), ...notches.flatMap((r) => [r.x0, r.x1])];\n  const cutsY = [...rects.flatMap((r) => [r.y0, r.y1]), ...notches.flatMap((r) => [r.y0, r.y1])];\n  const xs = uniqueSorted(cuts);\n  const ys = uniqueSorted(cutsY);\n  if (xs.length < 2 || ys.length < 2) return [];\n\n  // Cell-occupancy grid: a cell is filled if its centre lies in the rectangle union\n  // and in no notch (notches subtract material; they sit on the boundary so the\n  // result stays simply-connected).\n  const nx = xs.length - 1;\n  const ny = ys.length - 1;\n  const filled = new Set<number>();\n  for (let i = 0; i < nx; i += 1) {\n    const cx = ((xs[i] as number) + (xs[i + 1] as number)) / 2;\n    for (let j = 0; j < ny; j += 1) {\n      const cy = ((ys[j] as number) + (ys[j + 1] as number)) / 2;\n      const inRect = rects.some((r) => cx > r.x0 && cx < r.x1 && cy > r.y0 && cy < r.y1);\n      const inNotch = notches.some((r) => cx > r.x0 && cx < r.x1 && cy > r.y0 && cy < r.y1);\n      if (inRect && !inNotch) filled.add(i * ny + j);\n    }\n  }\n\n  // Collect boundary unit-edges (segments between adjacent grid nodes that border\n  // a filled and an unfilled cell), oriented CCW (filled cell on the left).\n  const segs: { a: Pt2; b: Pt2 }[] = [];\n  const isFilled = (i: number, j: number): boolean =>\n    i >= 0 && i < nx && j >= 0 && j < ny && filled.has(i * ny + j);\n\n  for (let i = 0; i < nx; i += 1) {\n    for (let j = 0; j < ny; j += 1) {\n      if (!isFilled(i, j)) continue;\n      const x0 = xs[i] as number;\n      const x1 = xs[i + 1] as number;\n      const y0 = ys[j] as number;\n      const y1 = ys[j + 1] as number;\n      // Bottom edge: boundary if cell below is empty. CCW → left-to-right.\n      if (!isFilled(i, j - 1)) segs.push({ a: [x0, y0], b: [x1, y0] });\n      // Top edge: boundary if cell above empty. CCW → right-to-left.\n      if (!isFilled(i, j + 1)) segs.push({ a: [x1, y1], b: [x0, y1] });\n      // Left edge: boundary if cell left empty. CCW → top-to-bottom.\n      if (!isFilled(i - 1, j)) segs.push({ a: [x0, y1], b: [x0, y0] });\n      // Right edge: boundary if cell right empty. CCW → bottom-to-top.\n      if (!isFilled(i + 1, j)) segs.push({ a: [x1, y0], b: [x1, y1] });\n    }\n  }\n\n  return traceLoop(segs);\n}\n\n/**\n * Area of material removed by the relief notches: the portion of each notch that\n * overlaps the rectangle union, summed over a shared cell grid so overlapping\n * notches (e.g. two corner reliefs meeting) are not double-counted.\n */\nfunction removedNotchArea(rects: Rect[], notches: Rect[]): number {\n  if (notches.length === 0) return 0;\n  const xs = uniqueSorted([\n    ...rects.flatMap((r) => [r.x0, r.x1]),\n    ...notches.flatMap((r) => [r.x0, r.x1]),\n  ]);\n  const ys = uniqueSorted([\n    ...rects.flatMap((r) => [r.y0, r.y1]),\n    ...notches.flatMap((r) => [r.y0, r.y1]),\n  ]);\n  let area = 0;\n  for (let i = 0; i + 1 < xs.length; i += 1) {\n    const x0 = xs[i] as number;\n    const x1 = xs[i + 1] as number;\n    const cx = (x0 + x1) / 2;\n    for (let j = 0; j + 1 < ys.length; j += 1) {\n      const y0 = ys[j] as number;\n      const y1 = ys[j + 1] as number;\n      const cy = (y0 + y1) / 2;\n      const inRect = rects.some((r) => cx > r.x0 && cx < r.x1 && cy > r.y0 && cy < r.y1);\n      const inNotch = notches.some((r) => cx > r.x0 && cx < r.x1 && cy > r.y0 && cy < r.y1);\n      if (inRect && inNotch) area += (x1 - x0) * (y1 - y0);\n    }\n  }\n  return area;\n}\n\n/** Chain oriented boundary segments into a single loop, dropping collinear points. */\nfunction traceLoop(segs: { a: Pt2; b: Pt2 }[]): Pt2[] {\n  if (segs.length === 0) return [];\n  const key = (p: Pt2): string => `${p[0]}|${p[1]}`;\n  const from = new Map<string, Pt2>();\n  for (const s of segs) from.set(key(s.a), s.b);\n\n  const startSeg = segs[0] as { a: Pt2; b: Pt2 };\n  const start = startSeg.a;\n  const raw: Pt2[] = [start];\n  let cur = startSeg.b;\n  let guard = 0;\n  const limit = segs.length + 4;\n  while (key(cur) !== key(start) && guard < limit) {\n    raw.push(cur);\n    const next = from.get(key(cur));\n    if (next === undefined) break;\n    cur = next;\n    guard += 1;\n  }\n\n  // Drop collinear interior points so consecutive edges aren't degenerate.\n  const out: Pt2[] = [];\n  for (let i = 0; i < raw.length; i += 1) {\n    const prev = raw[(i - 1 + raw.length) % raw.length] as Pt2;\n    const here = raw[i] as Pt2;\n    const next = raw[(i + 1) % raw.length] as Pt2;\n    const d1x = here[0] - prev[0];\n    const d1y = here[1] - prev[1];\n    const d2x = next[0] - here[0];\n    const d2y = next[1] - here[1];\n    if (Math.abs(d1x * d2y - d1y * d2x) > 1e-9) out.push(here);\n  }\n  return out;\n}\n\nfunction uniqueSorted(values: number[]): number[] {\n  const sorted = [...values].sort((a, b) => a - b);\n  const out: number[] = [];\n  for (const v of sorted) {\n    const last = out[out.length - 1];\n    if (last === undefined || Math.abs(v - last) > 1e-9) out.push(v);\n  }\n  return out;\n}\n\n/**\n * Build the bend report for a laid-out tree: one entry per placed flange with its\n * angle, radius, allowance, flat length, and direction, plus the overall\n * bounding-box span of the developed pattern.\n *\n * @param layout - the tree layout produced by {@link layoutTree}\n * @returns the bend entries and the total flat pattern size\n */\nexport function reportFromLayout(layout: TreeLayout): BendReport {\n  const flanges = layout.flats.filter((p): p is PlacedFlange => p.kind === 'flange');\n  const bends = flanges.map((f) => ({\n    id: f.id,\n    angleDeg: f.angleDeg,\n    radius: f.rule.innerRadius,\n    allowance: f.dev,\n    flatLength: f.length,\n    direction: f.direction,\n  }));\n\n  // totalFlatSize is the overall bounding-box span of the developed pattern, which\n  // for parts whose flanges extend into negative coordinates (xmin/ymin sides) is\n  // the max−min extent, not just the max.\n  let minX = 0;\n  let minY = 0;\n  let maxX = layout.baseLength;\n  let maxY = layout.width;\n  for (const r of layout.flats.map((p) => p.rect).concat(layout.strips)) {\n    if (r.x0 < minX) minX = r.x0;\n    if (r.y0 < minY) minY = r.y0;\n    if (r.x1 > maxX) maxX = r.x1;\n    if (r.y1 > maxY) maxY = r.y1;\n  }\n  return { bends, totalFlatSize: [maxX - minX, maxY - minY] };\n}\n"]}
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type { Wire, Edge } from './types.js';\nimport {type Result, ok, err, validationError, line, wireLoop, assembleWire} from '@faicad/faijs/api';\nimport type {\n  SheetMetalPart,\n  UnfoldResult,\n  FlatPattern,\n  BendReport,\n  SheetMetalWarning,\n  CornerMiter,\n  FlatSide,\n} from './types.js';\nimport { featureTree, type FeatureTree, ROOT_FLAT_ID } from './featureTreeFns.js';\nimport { developedLength } from './allowanceFns.js';\nimport { sideFromAxisDir } from './internal.js';\n\ntype Pt2 = [number, number];\n\n/**\n * Tree-driven analytic unfold of an arbitrary straight-bend part into its flat\n * pattern. Walks the feature tree in BFS order placing every flat in the flat\n * plane: the base occupies `[0,baseLength]×[0,width]`; each child flange lays a\n * developed-bend strip (width = neutral-axis arc length) along the parent edge it\n * folds from — respecting its offset/span along that edge — then its own flat past\n * the strip, perpendicular to the edge and pointing outward. The developed outline\n * is the rectilinear union of the base and every placed flat/strip rectangle,\n * emitted as a single closed morph wire. A recorded corner miter replaces the\n * shared reflex corner of two perpendicular base flanges with a 45° chamfer.\n * Closed profiles produce a SEAM_CUT warning (the cycle-closing bend is left\n * unfolded). Warnings ride inside the Ok payload.\n *\n * @param part - the sheet-metal part to develop into its flat pattern\n * @returns the flat pattern (outline, bend lines, holes, form cuts/markers/hinges,\n *   lofted developments, developed area), the bend report, and any warnings — or\n *   an error if the part cannot be unfolded\n */\nexport function unfold(part: SheetMetalPart): Result<UnfoldResult> {\n  const treeResult = featureTree(part);\n  if (!treeResult.ok) return treeResult;\n  const tree = treeResult.value;\n\n  const baseLength = part.baseLength;\n  if (!Number.isFinite(baseLength) || baseLength <= 0) {\n    return err(validationError('INVALID_BASE_LENGTH', `part baseLength must be positive, got ${baseLength}`));\n  }\n  const width = part.width;\n  if (!Number.isFinite(width) || width <= 0) {\n    return err(validationError('INVALID_WIDTH', `part width must be positive, got ${width}`));\n  }\n\n  const warnings: SheetMetalWarning[] = [...tree.warnings];\n\n  const layoutResult = layoutTree(part, tree, baseLength, width, (warning) => warnings.push(warning));\n  if (!layoutResult.ok) return layoutResult;\n  const layout = layoutResult.value;\n\n  for (const placed of layout.flats) {\n    if (placed.kind !== 'flange') continue;\n    if (part.thickness > 0 && placed.rule.innerRadius < part.thickness) {\n      warnings.push({\n        code: 'MIN_RADIUS',\n        message: `bend '${placed.id}' inner radius ${placed.rule.innerRadius} < thickness ${part.thickness}`,\n        featureId: placed.id,\n      });\n    }\n  }\n\n  // Contour-flange developed strips lay out straight along their base edge; compute\n  // them first so their rectangles join the outline union below.\n  const contourResult = buildContourDevelopments(part);\n  if (!contourResult.ok) return contourResult;\n\n  // Hems and jogs lay their multi-bend developed strips out straight along their\n  // region edge (the base or a flange), exactly like a contour flange.\n  const hemJogResult = buildHemJogDevelopments(part, layout);\n  if (!hemJogResult.ok) return hemJogResult;\n\n  const rects: Rect[] = [];\n  for (const placed of layout.flats) rects.push(placed.rect);\n  for (const strip of layout.strips) rects.push(strip);\n  for (const strip of contourResult.value.strips) rects.push(strip);\n  for (const strip of hemJogResult.value.strips) rects.push(strip);\n\n  // Tabs are additive protrusions: their developed rectangles join the outer-outline\n  // union and add to the developed area.\n  const tabRects: Rect[] = (part.tabs ?? []).map((t) => ({ x0: t.rect[0], y0: t.rect[1], x1: t.rect[2], y1: t.rect[3] }));\n  for (const r of tabRects) rects.push(r);\n\n  const notches: Rect[] = (part.reliefs ?? []).flatMap((relief) =>\n    relief.notches.map(([x0, y0, x1, y1]) => ({ x0, y0, x1, y1 }))\n  );\n  // The L-miter chamfer special-case can't express tabs either; once any tab is\n  // recorded, fall through to the rectilinear-union path (which absorbs tab rects).\n  // The 3D corner-miter cut still stands; only the developed chamfer is omitted.\n  const miters = tabRects.length > 0 ? [] : part.miters ?? [];\n  if (tabRects.length > 0 && (part.miters ?? []).length > 0) {\n    warnings.push({\n      code: 'MITER_NOT_DEVELOPED',\n      message: 'developed outline omits the corner-miter chamfer because a tab is present; the 3D miter cut is unaffected',\n    });\n  }\n  const outlineResult = buildOutline(rects, layout, miters, notches);\n  if (!outlineResult.ok) return outlineResult;\n  layout.developedArea -= removedNotchArea(rects, notches);\n  for (const t of part.tabs ?? []) layout.developedArea += t.area;\n\n  const holesResult = buildHoles(part);\n  if (!holesResult.ok) return holesResult;\n  for (const c of part.cutouts ?? []) layout.developedArea -= c.area;\n\n  const formsResult = buildForms(part);\n  if (!formsResult.ok) return formsResult;\n\n  const loftedResult = buildLoftedDevelopments(part);\n  if (!loftedResult.ok) return loftedResult;\n  for (const lf of part.loftedFlanges ?? []) {\n    layout.developedArea += lf.developedArea;\n    if (lf.approximate) {\n      warnings.push({\n        code: 'DEVELOPMENT_APPROXIMATE',\n        message: `lofted flange '${lf.id}' transition is not developable; its triangulated flat development is an approximation`,\n        featureId: lf.id,\n      });\n    }\n  }\n\n  for (const cf of part.contourFlanges ?? []) {\n    layout.developedArea += cf.developedLength * cf.span;\n  }\n\n  for (const h of part.hems ?? []) {\n    layout.developedArea += h.developedLength * h.span;\n  }\n  for (const j of part.jogs ?? []) {\n    layout.developedArea += j.developedLength * j.span;\n  }\n\n  const bendLines = layout.flats\n    .filter((p): p is PlacedFlange => p.kind === 'flange')\n    .map((p) => ({\n      id: p.id,\n      line: bendLineEdge(p),\n      angleDeg: p.angleDeg,\n      direction: p.direction,\n      // The child frame's v axis is the develop-out direction; into-parent is its\n      // negation. Correct for chained flanges too (it is local to the placement).\n      inward: [-p.frame.v[0], -p.frame.v[1]] as [number, number],\n    }))\n    .concat(contourResult.value.bendLines)\n    .concat(hemJogResult.value.bendLines);\n\n  const pattern: FlatPattern = {\n    outline: outlineResult.value,\n    bendLines,\n    holes: holesResult.value,\n    formCuts: formsResult.value.cuts,\n    formMarkers: formsResult.value.markers,\n    formHinges: formsResult.value.hinges,\n    loftedDevelopments: loftedResult.value,\n    developedArea: layout.developedArea,\n  };\n\n  const report = reportFromLayout(layout);\n\n  return ok({ pattern, report, warnings });\n}\n\n/** A placed flat rectangle in the developed (flat-pattern) plane. */\nexport interface Rect {\n  x0: number;\n  y0: number;\n  x1: number;\n  y1: number;\n}\n\n/** 2D frame of a placed flat: occupies [0,uLen]×[0,vLen] in (u,v) from `origin`. */\nexport interface Frame2 {\n  origin: Pt2;\n  u: Pt2;\n  v: Pt2;\n  uLen: number;\n  vLen: number;\n}\n\n/** A placed base flat: the root rectangle `[0,baseLength]×[0,width]`. */\nexport interface PlacedBase {\n  kind: 'base';\n  id: string;\n  rect: Rect;\n  frame: Frame2;\n}\n\n/** A placed flange flat: a developed strip laid along a parent edge plus its own flat. */\nexport interface PlacedFlange {\n  kind: 'flange';\n  id: string;\n  rect: Rect;\n  frame: Frame2;\n  /** Strip rectangle laid along the parent edge (developed bend). */\n  strip: Rect;\n  /** Bend line endpoints (along the parent edge, over the flange span). */\n  bendA: Pt2;\n  bendB: Pt2;\n  dev: number;\n  length: number;\n  span: number;\n  angleDeg: number;\n  direction: 'up' | 'down';\n  rule: { innerRadius: number; kFactor: number; allowance?: number | undefined };\n  /** True when this flange folds directly off the base and spans its full edge. */\n  baseFull: boolean;\n  side: FlatSide;\n}\n\n/** A placed flat in the developed plane: either the base or a flange. */\nexport type Placed = PlacedBase | PlacedFlange;\n\n/** The result of {@link layoutTree}: developed dimensions, placed flats, and strips. */\nexport interface TreeLayout {\n  baseLength: number;\n  width: number;\n  developedArea: number;\n  flats: Placed[];\n  strips: Rect[];\n}\n\n/**\n * Lay out the feature tree's flats in the flat plane, starting from the base and\n * placing each bend's child flange along its parent edge: a developed strip laid\n * outward from the edge, then the child's own flat. Produces the placed flats,\n * their strips, and the total developed area.\n *\n * @param part - the sheet-metal part whose features are laid out\n * @param tree - the feature tree built from the part\n * @param baseLength - length of the base flat (u extent)\n * @param width - width of the base flat (v extent)\n * @param onWarning - optional callback invoked for warnings raised while unfolding\n * @returns the laid-out flats, strips, and developed area, or an error if a\n *   referenced flat has no flange feature or is missing from the layout\n */\nexport function layoutTree(\n  part: SheetMetalPart,\n  tree: FeatureTree,\n  baseLength: number,\n  width: number,\n  onWarning?: (warning: SheetMetalWarning) => void\n): Result<TreeLayout> {\n  const frames = new Map<string, Frame2>();\n  frames.set(ROOT_FLAT_ID, {\n    origin: [0, 0],\n    u: [1, 0],\n    v: [0, 1],\n    uLen: baseLength,\n    vLen: width,\n  });\n\n  const flats: Placed[] = [\n    {\n      kind: 'base',\n      id: ROOT_FLAT_ID,\n      frame: frames.get(ROOT_FLAT_ID) as Frame2,\n      rect: rectOf(frames.get(ROOT_FLAT_ID) as Frame2),\n    },\n  ];\n  const strips: Rect[] = [];\n  let developedArea = baseLength * width;\n\n  for (const treeBend of tree.bends) {\n    const childNode = tree.nodes.get(treeBend.child);\n    if (childNode === undefined || childNode.flange === undefined) {\n      return err(\n        validationError('UNKNOWN_FLAT', `child flat '${treeBend.child}' has no flange feature`)\n      );\n    }\n    const flange = childNode.flange;\n    const parentFrame = frames.get(treeBend.parent);\n    if (parentFrame === undefined) {\n      return err(\n        validationError('UNKNOWN_FLAT', `parent flat '${treeBend.parent}' missing from layout`)\n      );\n    }\n\n    const devResult = developedLength(treeBend.bend.angleDeg, part.thickness, treeBend.bend.rule, onWarning);\n    if (!devResult.ok) return devResult;\n    const dev = devResult.value;\n\n    // Authored parts always record `baseEdge.side`; hand-built fixtures may encode\n    // the develop direction only via the bend axis, so fall back to that.\n    const side: FlatSide = flange.baseEdge.side ?? sideFromAxisDir(treeBend.bend.axisDir) ?? 'xmax';\n    const offset = flange.offset ?? flange.baseEdge.offset ?? 0;\n    const span = flange.span;\n    const length = flange.length;\n\n    const placed = placeChild(flange.id, parentFrame, side, offset, span, dev, length, {\n      angleDeg: treeBend.bend.angleDeg,\n      direction: treeBend.bend.direction,\n      rule: treeBend.bend.rule,\n      baseFull: treeBend.parent === ROOT_FLAT_ID && offset <= 1e-6 && span >= edgeLength(parentFrame, side) - 1e-6,\n      side,\n    });\n    frames.set(flange.id, placed.frame);\n    flats.push(placed);\n    strips.push(placed.strip);\n    developedArea += (dev + length) * span;\n  }\n\n  return ok({ baseLength, width, developedArea, flats, strips });\n}\n\nfunction edgeLength(f: Frame2, side: FlatSide): number {\n  return side === 'xmax' || side === 'xmin' ? f.vLen : f.uLen;\n}\n\n/**\n * Place a child flange off `parent`'s edge `side`. The strip (developed bend) is\n * laid from the edge outward by `dev`; the child flat follows for `length`. The\n * child's own 2D frame starts past the strip so grandchildren chain correctly.\n */\nfunction placeChild(\n  id: string,\n  parent: Frame2,\n  side: FlatSide,\n  offset: number,\n  span: number,\n  dev: number,\n  length: number,\n  meta: {\n    angleDeg: number;\n    direction: 'up' | 'down';\n    rule: { innerRadius: number; kFactor: number; allowance?: number | undefined };\n    baseFull: boolean;\n    side: FlatSide;\n  }\n): PlacedFlange {\n  // Edge basis in 2D: `along` runs the edge (bend axis), `out` points outward.\n  const { along, out, edgeOrigin } = edgeBasis2(parent, side);\n\n  const base = add2(edgeOrigin, scale2(along, offset));\n  const bendA = base;\n  const bendB = add2(base, scale2(along, span));\n\n  const stripFar = add2(base, scale2(out, dev));\n\n  const strip = rectFromCorners(base, add2(bendB, scale2(out, dev)));\n  const flatRect = rectFromCorners(stripFar, add2(add2(stripFar, scale2(along, span)), scale2(out, length)));\n\n  const childFrame: Frame2 = {\n    origin: stripFar,\n    u: along,\n    v: out,\n    uLen: span,\n    vLen: length,\n  };\n\n  return {\n    kind: 'flange',\n    id,\n    frame: childFrame,\n    rect: flatRect,\n    strip,\n    bendA,\n    bendB,\n    dev,\n    length,\n    span,\n    angleDeg: meta.angleDeg,\n    direction: meta.direction,\n    rule: meta.rule,\n    baseFull: meta.baseFull,\n    side: meta.side,\n  };\n}\n\n/**\n * Edge origin and along/out unit directions for one side of a 2D frame. `along`\n * runs along the edge (the bend axis), `out` points outward from the frame, and\n * `edgeOrigin` is the starting corner of that edge.\n *\n * @param f - the 2D frame whose edge basis is computed\n * @param side - which side of the frame ('xmax' | 'xmin' | 'ymax' | 'ymin')\n * @returns the along/out unit directions and the edge's origin corner\n */\nexport function edgeBasis2(f: Frame2, side: FlatSide): { along: Pt2; out: Pt2; edgeOrigin: Pt2 } {\n  const uTop = add2(f.origin, scale2(f.u, f.uLen));\n  const vTop = add2(f.origin, scale2(f.v, f.vLen));\n  switch (side) {\n    case 'xmax':\n      return { along: f.v, out: f.u, edgeOrigin: uTop };\n    case 'xmin':\n      return { along: f.v, out: neg2(f.u), edgeOrigin: f.origin };\n    case 'ymax':\n      return { along: f.u, out: f.v, edgeOrigin: vTop };\n    case 'ymin':\n      return { along: f.u, out: neg2(f.v), edgeOrigin: f.origin };\n    default:\n      return side satisfies never;\n  }\n}\n\nfunction bendLineEdge(p: PlacedFlange): Edge {\n  return line([p.bendA[0], p.bendA[1], 0], [p.bendB[0], p.bendB[1], 0]);\n}\n\n/**\n * One closed developed-plane {@link Wire} per recorded cutout, traced from the\n * feature's already-mapped `loop` (which {@link addCutout} positioned via the\n * region's developed frame, so the loop sits at the cutout's matching flat-pattern\n * spot). Emitted as interior holes of the pattern; the outer outline is unchanged.\n */\nfunction buildHoles(part: SheetMetalPart): Result<Wire[]> {\n  const wires: Wire[] = [];\n  for (const c of part.cutouts ?? []) {\n    const loop = c.loop;\n    if (loop.length < 3) {\n      return err(validationError('CUTOUT_LOOP_TOO_SMALL', `cutout loop has ${loop.length} points, need ≥ 3`));\n    }\n    const edges: Edge[] = [];\n    for (let i = 0; i < loop.length; i += 1) {\n      const a = loop[i];\n      const b = loop[(i + 1) % loop.length];\n      if (a === undefined || b === undefined) {\n        return err(validationError('CUTOUT_LOOP_FAILED', 'failed to index cutout loop'));\n      }\n      edges.push(line([a[0], a[1], 0], [b[0], b[1], 0]));\n    }\n    const wire = wireLoop(edges);\n    if (!wire.ok) return wire;\n    wires.push(wire.value);\n  }\n  return ok(wires);\n}\n\ninterface FormWires {\n  cuts: Wire[];\n  markers: Wire[];\n  hinges: Edge[];\n}\n\n/**\n * Developed-plane wires for recorded form features: each louver U-cut and emboss\n * footprint as a closed {@link Wire}, plus each louver hinge as an {@link Edge}. The\n * loops were already mapped into developed coordinates when the form was recorded\n * (via the region's developed frame), so this just traces them. Forms are net-\n * material-neutral, so the outer outline and developed area are untouched.\n */\nfunction buildForms(part: SheetMetalPart): Result<FormWires> {\n  const cuts: Wire[] = [];\n  const markers: Wire[] = [];\n  const hinges: Edge[] = [];\n  for (const form of part.forms ?? []) {\n    for (const path of form.cuts) {\n      const cutWire = openPathWire(path);\n      if (!cutWire.ok) return cutWire;\n      cuts.push(cutWire.value);\n    }\n    for (const loop of form.markers) {\n      const markerWire = closedLoopWire(loop);\n      if (!markerWire.ok) return markerWire;\n      markers.push(markerWire.value);\n    }\n    if (form.hinge !== undefined) {\n      const [a, b] = form.hinge;\n      hinges.push(line([a[0], a[1], 0], [b[0], b[1], 0]));\n    }\n  }\n  return ok({ cuts, markers, hinges });\n}\n\n/**\n * Closed developed-plane {@link Wire}s for recorded lofted/ruled transition flanges.\n * Each feature's triangulated `developedLoop` was already laid out flat when the\n * flange was authored, so this just traces it into a wire; the boundary is non-\n * rectilinear so it rides separately from the rectilinear-union outline.\n */\nfunction buildLoftedDevelopments(part: SheetMetalPart): Result<Wire[]> {\n  const wires: Wire[] = [];\n  for (const lf of part.loftedFlanges ?? []) {\n    const w = closedLoopWire(lf.developedLoop);\n    if (!w.ok) return w;\n    wires.push(w.value);\n  }\n  return ok(wires);\n}\n\ninterface ContourDevelopments {\n  /** Developed strip rectangles (one per contour flange) for the outline union. */\n  strips: Rect[];\n  /** Developed bend lines (one per arc segment) in the flat pattern. */\n  bendLines: FlatPattern['bendLines'];\n}\n\n/**\n * Lay each recorded contour flange's developed strip out STRAIGHT along its base\n * edge: a rectangle `span` wide along the edge by `developedLength` out from it,\n * returned for the outer-outline union. One bend line per arc segment is placed at\n * that segment's cumulative developed offset out from the base edge — the EXACT\n * arc-length sum, so the strip length equals Σ segment developed lengths with no\n * error.\n */\nfunction buildContourDevelopments(part: SheetMetalPart): Result<ContourDevelopments> {\n  const strips: Rect[] = [];\n  const bendLines: FlatPattern['bendLines'] = [];\n  const baseFrame: Frame2 = {\n    origin: [0, 0],\n    u: [1, 0],\n    v: [0, 1],\n    uLen: part.baseLength,\n    vLen: part.width,\n  };\n\n  for (const cf of part.contourFlanges ?? []) {\n    const { along, out, edgeOrigin } = edgeBasis2(baseFrame, cf.side);\n    const base = add2(edgeOrigin, scale2(along, cf.offset));\n    strips.push(\n      rectFromCorners(base, add2(add2(base, scale2(along, cf.span)), scale2(out, cf.developedLength)))\n    );\n\n    let cumulative = 0;\n    for (const seg of cf.segments) {\n      if (seg.kind === 'arc') {\n        const a = add2(base, scale2(out, cumulative));\n        const b = add2(a, scale2(along, cf.span));\n        bendLines.push({\n          id: seg.bendId ?? cf.id,\n          line: line([a[0], a[1], 0], [b[0], b[1], 0]),\n          angleDeg: seg.angleDeg ?? 0,\n          direction: seg.direction ?? 'up',\n          inward: [-out[0], -out[1]] as [number, number],\n        });\n      }\n      cumulative += seg.dev;\n    }\n  }\n  return ok({ strips, bendLines });\n}\n\ninterface HemJogDevelopments {\n  /** Developed strip rectangles (one per hem/jog) for the outline union. */\n  strips: Rect[];\n  /** Developed bend lines (one per curl/step sub-bend) in the flat pattern. */\n  bendLines: FlatPattern['bendLines'];\n}\n\n/**\n * Lay each recorded hem and jog developed strip out STRAIGHT along its region edge\n * (the base or a flange), mirroring {@link buildContourDevelopments}. The region's\n * developed-plane {@link Frame2} comes from the tree layout (so a hem on a flange\n * lands on that flange's developed face). Each sub-bend (a hem curl arc or a jog\n * step arc) gets a bend line at its EXACT cumulative developed offset out from the\n * edge — Σ segment developed lengths, so the strip length is exact.\n */\nfunction buildHemJogDevelopments(part: SheetMetalPart, layout: TreeLayout): Result<HemJogDevelopments> {\n  const strips: Rect[] = [];\n  const bendLines: FlatPattern['bendLines'] = [];\n\n  const frameFor = (region: string): Frame2 | undefined => {\n    const id = region === 'base' || region === 'face-0' ? ROOT_FLAT_ID : region;\n    for (const p of layout.flats) {\n      if (p.id === id) return p.frame;\n    }\n    return undefined;\n  };\n\n  interface Strip {\n    region: string;\n    side: FlatSide;\n    offset: number;\n    span: number;\n    developedLength: number;\n    segments: {\n      kind: 'line' | 'arc';\n      dev: number;\n      angleDeg?: number | undefined;\n      direction?: 'up' | 'down' | undefined;\n      bendId?: string | undefined;\n    }[];\n  }\n  const allStrips: Strip[] = [\n    ...(part.hems ?? []).map((h) => ({\n      region: h.region,\n      side: h.side,\n      offset: h.offset,\n      span: h.span,\n      developedLength: h.developedLength,\n      segments: h.segments,\n    })),\n    ...(part.jogs ?? []).map((j) => ({\n      region: j.region,\n      side: j.side,\n      offset: j.offset,\n      span: j.span,\n      developedLength: j.developedLength,\n      segments: j.segments,\n    })),\n  ];\n\n  for (const s of allStrips) {\n    const regionFrame = frameFor(s.region);\n    if (regionFrame === undefined) {\n      return err(validationError('UNKNOWN_HEMJOG_REGION', `hem/jog region '${s.region}' missing from layout`));\n    }\n    const { along, out, edgeOrigin } = edgeBasis2(regionFrame, s.side);\n    const base = add2(edgeOrigin, scale2(along, s.offset));\n    strips.push(rectFromCorners(base, add2(add2(base, scale2(along, s.span)), scale2(out, s.developedLength))));\n\n    let cumulative = 0;\n    for (const seg of s.segments) {\n      if (seg.kind === 'arc') {\n        const a = add2(base, scale2(out, cumulative));\n        const b = add2(a, scale2(along, s.span));\n        bendLines.push({\n          id: seg.bendId ?? s.region,\n          line: line([a[0], a[1], 0], [b[0], b[1], 0]),\n          angleDeg: seg.angleDeg ?? 0,\n          direction: seg.direction ?? 'up',\n          inward: [-out[0], -out[1]] as [number, number],\n        });\n      }\n      cumulative += seg.dev;\n    }\n  }\n  return ok({ strips, bendLines });\n}\n\n/** Trace a closed developed-plane loop (≥ 3 points) into a morph {@link Wire}. */\nfunction closedLoopWire(loop: Pt2[]): Result<Wire> {\n  if (loop.length < 3) {\n    return err(validationError('FORM_LOOP_TOO_SMALL', `form loop has ${loop.length} points, need ≥ 3`));\n  }\n  const edges: Edge[] = [];\n  for (let i = 0; i < loop.length; i += 1) {\n    const a = loop[i];\n    const b = loop[(i + 1) % loop.length];\n    if (a === undefined || b === undefined) {\n      return err(validationError('FORM_LOOP_FAILED', 'failed to index form loop'));\n    }\n    edges.push(line([a[0], a[1], 0], [b[0], b[1], 0]));\n  }\n  return wireLoop(edges);\n}\n\n/** Trace an OPEN developed-plane path (≥ 2 points) into a morph {@link Wire}. */\nfunction openPathWire(path: Pt2[]): Result<Wire> {\n  if (path.length < 2) {\n    return err(validationError('FORM_PATH_TOO_SHORT', `form cut path has ${path.length} points, need ≥ 2`));\n  }\n  const edges: Edge[] = [];\n  for (let i = 0; i + 1 < path.length; i += 1) {\n    const a = path[i];\n    const b = path[i + 1];\n    if (a === undefined || b === undefined) {\n      return err(validationError('FORM_LOOP_FAILED', 'failed to index form cut path'));\n    }\n    edges.push(line([a[0], a[1], 0], [b[0], b[1], 0]));\n  }\n  return assembleWire(edges);\n}\n\nfunction rectOf(f: Frame2): Rect {\n  const c0 = f.origin;\n  const c1 = add2(add2(f.origin, scale2(f.u, f.uLen)), scale2(f.v, f.vLen));\n  return rectFromCorners(c0, c1);\n}\n\nfunction rectFromCorners(a: Pt2, b: Pt2): Rect {\n  return {\n    x0: Math.min(a[0], b[0]),\n    y0: Math.min(a[1], b[1]),\n    x1: Math.max(a[0], b[0]),\n    y1: Math.max(a[1], b[1]),\n  };\n}\n\nfunction add2(a: Pt2, b: Pt2): Pt2 {\n  return [a[0] + b[0], a[1] + b[1]];\n}\nfunction scale2(a: Pt2, s: number): Pt2 {\n  return [a[0] * s, a[1] * s];\n}\nfunction neg2(a: Pt2): Pt2 {\n  return [-a[0], -a[1]];\n}\n\n/**\n * Outline of the developed pattern. For the simple two-perpendicular-flange L\n * (base + an east + a north flange) a recorded corner miter chamfers the reflex\n * vertex; otherwise the outline is the rectilinear union of all placed rectangles\n * emitted as one closed loop. Holes are not possible for the supported shapes\n * (every arm attaches to the simply-connected base or a chain thereof).\n */\nfunction buildOutline(\n  rects: Rect[],\n  layout: TreeLayout,\n  miters: CornerMiter[],\n  notches: Rect[]\n): Result<Wire> {\n  // The lShapedMiter chamfer special-case can't express a notch, so once any relief\n  // is recorded fall through to the rectilinear-union path (which subtracts notches).\n  const miterCorners = notches.length > 0 ? undefined : lShapedMiter(layout, miters);\n  const corners = miterCorners ?? rectilinearUnion(rects, notches);\n  if (corners.length < 3) {\n    return err(validationError('OUTLINE_BUILD_FAILED', 'developed outline has fewer than 3 vertices'));\n  }\n  const edges: Edge[] = [];\n  for (let i = 0; i < corners.length; i += 1) {\n    const from = corners[i];\n    const to = corners[(i + 1) % corners.length];\n    if (from === undefined || to === undefined) {\n      return err(validationError('OUTLINE_BUILD_FAILED', 'failed to index outline corners'));\n    }\n    edges.push(line([from[0], from[1], 0], [to[0], to[1], 0]));\n  }\n  return wireLoop(edges);\n}\n\n/**\n * Special-case the classic L: a base with exactly one east (+X) and one north\n * (+Y) full-span flange and a recorded miter between them. Returns the chamfered\n * hexagon; `undefined` if this isn't that shape (fall back to the union outline).\n */\nfunction lShapedMiter(layout: TreeLayout, miters: CornerMiter[]): Pt2[] | undefined {\n  const flanges = layout.flats.filter((p): p is PlacedFlange => p.kind === 'flange');\n  if (flanges.length !== 2) return undefined;\n  const east = flanges.find((f) => f.baseFull && f.side === 'xmax');\n  const north = flanges.find((f) => f.baseFull && f.side === 'ymax');\n  if (east === undefined || north === undefined) return undefined;\n\n  const baseLength = layout.baseLength;\n  const width = layout.width;\n  const maxX = baseLength + east.dev + east.length;\n  const maxY = width + north.dev + north.length;\n  const gap = miterGapFor(miters, east.id, north.id);\n\n  if (gap === undefined || gap <= 0) {\n    return [\n      [0, 0],\n      [maxX, 0],\n      [maxX, width],\n      [baseLength, width],\n      [baseLength, maxY],\n      [0, maxY],\n    ];\n  }\n  return [\n    [0, 0],\n    [maxX, 0],\n    [maxX, width],\n    [baseLength + gap, width],\n    [baseLength, width + gap],\n    [baseLength, maxY],\n    [0, maxY],\n  ];\n}\n\nfunction miterGapFor(miters: CornerMiter[], aId: string, bId: string): number | undefined {\n  for (const m of miters) {\n    if ((m.flangeA === aId && m.flangeB === bId) || (m.flangeA === bId && m.flangeB === aId)) {\n      return m.gap;\n    }\n  }\n  return undefined;\n}\n\n/**\n * Outline loop of the union of axis-aligned rectangles, assuming the union is a\n * single simply-connected rectilinear region (true for every shape this package\n * authors: arms attached to a connected base). Built by a vertical-line sweep\n * tracking the covered y-spans, then tracing the boundary contour. The sweep emits\n * a CCW loop of corner points with no collinear duplicates.\n */\nfunction rectilinearUnion(rects: Rect[], notches: Rect[] = []): Pt2[] {\n  const cuts = [...rects.flatMap((r) => [r.x0, r.x1]), ...notches.flatMap((r) => [r.x0, r.x1])];\n  const cutsY = [...rects.flatMap((r) => [r.y0, r.y1]), ...notches.flatMap((r) => [r.y0, r.y1])];\n  const xs = uniqueSorted(cuts);\n  const ys = uniqueSorted(cutsY);\n  if (xs.length < 2 || ys.length < 2) return [];\n\n  // Cell-occupancy grid: a cell is filled if its centre lies in the rectangle union\n  // and in no notch (notches subtract material; they sit on the boundary so the\n  // result stays simply-connected).\n  const nx = xs.length - 1;\n  const ny = ys.length - 1;\n  const filled = new Set<number>();\n  for (let i = 0; i < nx; i += 1) {\n    const cx = ((xs[i] as number) + (xs[i + 1] as number)) / 2;\n    for (let j = 0; j < ny; j += 1) {\n      const cy = ((ys[j] as number) + (ys[j + 1] as number)) / 2;\n      const inRect = rects.some((r) => cx > r.x0 && cx < r.x1 && cy > r.y0 && cy < r.y1);\n      const inNotch = notches.some((r) => cx > r.x0 && cx < r.x1 && cy > r.y0 && cy < r.y1);\n      if (inRect && !inNotch) filled.add(i * ny + j);\n    }\n  }\n\n  // Collect boundary unit-edges (segments between adjacent grid nodes that border\n  // a filled and an unfilled cell), oriented CCW (filled cell on the left).\n  const segs: { a: Pt2; b: Pt2 }[] = [];\n  const isFilled = (i: number, j: number): boolean =>\n    i >= 0 && i < nx && j >= 0 && j < ny && filled.has(i * ny + j);\n\n  for (let i = 0; i < nx; i += 1) {\n    for (let j = 0; j < ny; j += 1) {\n      if (!isFilled(i, j)) continue;\n      const x0 = xs[i] as number;\n      const x1 = xs[i + 1] as number;\n      const y0 = ys[j] as number;\n      const y1 = ys[j + 1] as number;\n      // Bottom edge: boundary if cell below is empty. CCW → left-to-right.\n      if (!isFilled(i, j - 1)) segs.push({ a: [x0, y0], b: [x1, y0] });\n      // Top edge: boundary if cell above empty. CCW → right-to-left.\n      if (!isFilled(i, j + 1)) segs.push({ a: [x1, y1], b: [x0, y1] });\n      // Left edge: boundary if cell left empty. CCW → top-to-bottom.\n      if (!isFilled(i - 1, j)) segs.push({ a: [x0, y1], b: [x0, y0] });\n      // Right edge: boundary if cell right empty. CCW → bottom-to-top.\n      if (!isFilled(i + 1, j)) segs.push({ a: [x1, y0], b: [x1, y1] });\n    }\n  }\n\n  return traceLoop(segs);\n}\n\n/**\n * Area of material removed by the relief notches: the portion of each notch that\n * overlaps the rectangle union, summed over a shared cell grid so overlapping\n * notches (e.g. two corner reliefs meeting) are not double-counted.\n */\nfunction removedNotchArea(rects: Rect[], notches: Rect[]): number {\n  if (notches.length === 0) return 0;\n  const xs = uniqueSorted([\n    ...rects.flatMap((r) => [r.x0, r.x1]),\n    ...notches.flatMap((r) => [r.x0, r.x1]),\n  ]);\n  const ys = uniqueSorted([\n    ...rects.flatMap((r) => [r.y0, r.y1]),\n    ...notches.flatMap((r) => [r.y0, r.y1]),\n  ]);\n  let area = 0;\n  for (let i = 0; i + 1 < xs.length; i += 1) {\n    const x0 = xs[i] as number;\n    const x1 = xs[i + 1] as number;\n    const cx = (x0 + x1) / 2;\n    for (let j = 0; j + 1 < ys.length; j += 1) {\n      const y0 = ys[j] as number;\n      const y1 = ys[j + 1] as number;\n      const cy = (y0 + y1) / 2;\n      const inRect = rects.some((r) => cx > r.x0 && cx < r.x1 && cy > r.y0 && cy < r.y1);\n      const inNotch = notches.some((r) => cx > r.x0 && cx < r.x1 && cy > r.y0 && cy < r.y1);\n      if (inRect && inNotch) area += (x1 - x0) * (y1 - y0);\n    }\n  }\n  return area;\n}\n\n/** Chain oriented boundary segments into a single loop, dropping collinear points. */\nfunction traceLoop(segs: { a: Pt2; b: Pt2 }[]): Pt2[] {\n  if (segs.length === 0) return [];\n  const key = (p: Pt2): string => `${p[0]}|${p[1]}`;\n  const from = new Map<string, Pt2>();\n  for (const s of segs) from.set(key(s.a), s.b);\n\n  const startSeg = segs[0] as { a: Pt2; b: Pt2 };\n  const start = startSeg.a;\n  const raw: Pt2[] = [start];\n  let cur = startSeg.b;\n  let guard = 0;\n  const limit = segs.length + 4;\n  while (key(cur) !== key(start) && guard < limit) {\n    raw.push(cur);\n    const next = from.get(key(cur));\n    if (next === undefined) break;\n    cur = next;\n    guard += 1;\n  }\n\n  // Drop collinear interior points so consecutive edges aren't degenerate.\n  const out: Pt2[] = [];\n  for (let i = 0; i < raw.length; i += 1) {\n    const prev = raw[(i - 1 + raw.length) % raw.length] as Pt2;\n    const here = raw[i] as Pt2;\n    const next = raw[(i + 1) % raw.length] as Pt2;\n    const d1x = here[0] - prev[0];\n    const d1y = here[1] - prev[1];\n    const d2x = next[0] - here[0];\n    const d2y = next[1] - here[1];\n    if (Math.abs(d1x * d2y - d1y * d2x) > 1e-9) out.push(here);\n  }\n  return out;\n}\n\nfunction uniqueSorted(values: number[]): number[] {\n  const sorted = [...values].sort((a, b) => a - b);\n  const out: number[] = [];\n  for (const v of sorted) {\n    const last = out[out.length - 1];\n    if (last === undefined || Math.abs(v - last) > 1e-9) out.push(v);\n  }\n  return out;\n}\n\n/**\n * Build the bend report for a laid-out tree: one entry per placed flange with its\n * angle, radius, allowance, flat length, and direction, plus the overall\n * bounding-box span of the developed pattern.\n *\n * @param layout - the tree layout produced by {@link layoutTree}\n * @returns the bend entries and the total flat pattern size\n */\nexport function reportFromLayout(layout: TreeLayout): BendReport {\n  const flanges = layout.flats.filter((p): p is PlacedFlange => p.kind === 'flange');\n  const bends = flanges.map((f) => ({\n    id: f.id,\n    angleDeg: f.angleDeg,\n    radius: f.rule.innerRadius,\n    allowance: f.dev,\n    flatLength: f.length,\n    direction: f.direction,\n  }));\n\n  // totalFlatSize is the overall bounding-box span of the developed pattern, which\n  // for parts whose flanges extend into negative coordinates (xmin/ymin sides) is\n  // the max−min extent, not just the max.\n  let minX = 0;\n  let minY = 0;\n  let maxX = layout.baseLength;\n  let maxY = layout.width;\n  for (const r of layout.flats.map((p) => p.rect).concat(layout.strips)) {\n    if (r.x0 < minX) minX = r.x0;\n    if (r.y0 < minY) minY = r.y0;\n    if (r.x1 > maxX) maxX = r.x1;\n    if (r.y1 > maxY) maxY = r.y1;\n  }\n  return { bends, totalFlatSize: [maxX - minX, maxY - minY] };\n}\n"]}

package/dist/validateFns.d.ts.map

@@ -1 +1 @@
-{"version":3,"file":"validateFns.d.ts","sourceRoot":"","sources":["../src/validateFns.ts"],"names":[],"mappings":"AAWA,OAAO,KAAK,EAAe,cAAc,EAAE,iBAAiB,EAAE,MAAM,YAAY,CAAC;AAKjF;;;;;;;;;;;;;;GAcG;AACH,wBAAgB,YAAY,CAAC,IAAI,EAAE,cAAc,GAAG,iBAAiB,EAAE,CAMtE"}
+{"version":3,"file":"validateFns.d.ts","sourceRoot":"","sources":["../src/validateFns.ts"],"names":[],"mappings":"AAGA,OAAO,KAAK,EAAe,cAAc,EAAE,iBAAiB,EAAE,MAAM,YAAY,CAAC;AAKjF;;;;;;;;;;;;;;GAcG;AACH,wBAAgB,YAAY,CAAC,IAAI,EAAE,cAAc,GAAG,iBAAiB,EAAE,CAMtE"}

package/dist/validateFns.js

@@ -1,4 +1,5 @@
-import { isValid, measureVolume, getBounds, vecNormalize, vecAdd, vecScale, vecCross, } from '@faicad/faijs/brepjs-compat';
+import { getBounds } from './geometryOps.js';
+import { isValid, measureVolume, vecNormalize, vecAdd, vecScale, vecCross } from '@faicad/faijs/api';
 import { ROOT_FLAT_ID } from './featureTreeFns.js';
 const OVERLAP_TOL = 1e-6;
 /**
@@ -32,14 +33,11 @@ function checkSolid(part) {
         return [{ code: 'INVALID_SOLID', message: 'folded solid failed kernel validity check' }];
     }
     const vol = measureVolume(solid);
-    if (!vol.ok) {
-        return [{ code: 'INVALID_SOLID', message: 'folded solid volume could not be measured' }];
-    }
-    if (vol.value <= 0) {
+    if (vol <= 0) {
         return [
             {
                 code: 'INVALID_SOLID',
-                message: `folded solid has non-positive volume ${vol.value}`,
+                message: `folded solid has non-positive volume ${vol}`,
             },
         ];
     }

package/dist/validateFns.js.map

@@ -1 +1 @@
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{\n  type Vec3,\n  type Bounds3D,\n  isValid,\n  measureVolume,\n  getBounds,\n  vecNormalize,\n  vecAdd,\n  vecScale,\n  vecCross,\n} from '@faicad/faijs/brepjs-compat';\nimport type { BendFeature, SheetMetalPart, SheetMetalWarning } from './types.js';\nimport { ROOT_FLAT_ID } from './featureTreeFns.js';\n\nconst OVERLAP_TOL = 1e-6;\n\n/**\n * Manufacturability checks for an authored sheet-metal part. Returns a list of\n * {@link SheetMetalWarning} — these are advisory, never errors: a part with\n * warnings is still produced and exportable. Three checks per plan §6:\n *\n *  - `INVALID_SOLID`: the folded solid is missing, fails kernel validity, or has\n *    no positive volume.\n *  - `COLLISION`: two flanges' axis-aligned bounding boxes overlap once folded —\n *    the cheap interference signal for corners that need a miter or relief cut.\n *  - `MIN_RADIUS`: a bend's inner radius is below one material thickness\n *    (`R < 1×T`), the standard minimum-bend-radius rule of thumb.\n *\n * @param part - the sheet metal part to validate.\n * @returns the list of warnings (empty if valid).\n */\nexport function validatePart(part: SheetMetalPart): SheetMetalWarning[] {\n  const warnings: SheetMetalWarning[] = [];\n  warnings.push(...checkSolid(part));\n  warnings.push(...checkCollisions(part));\n  warnings.push(...checkMinRadius(part));\n  return warnings;\n}\n\nfunction checkSolid(part: SheetMetalPart): SheetMetalWarning[] {\n  const solid = part.solid;\n  if (solid === undefined) {\n    return [{ code: 'INVALID_SOLID', message: 'part has no folded solid' }];\n  }\n  if (!isValid(solid)) {\n    return [{ code: 'INVALID_SOLID', message: 'folded solid failed kernel validity check' }];\n  }\n  const vol = measureVolume(solid);\n  if (!vol.ok) {\n    return [{ code: 'INVALID_SOLID', message: 'folded solid volume could not be measured' }];\n  }\n  if (vol.value <= 0) {\n    return [\n      {\n        code: 'INVALID_SOLID',\n        message: `folded solid has non-positive volume ${vol.value}`,\n      },\n    ];\n  }\n  return [];\n}\n\nfunction checkMinRadius(part: SheetMetalPart): SheetMetalWarning[] {\n  const warnings: SheetMetalWarning[] = [];\n  if (!(part.thickness > 0)) return warnings;\n  for (const bend of part.bends) {\n    if (bend.id.startsWith('seam::')) continue;\n    if (bend.rule.innerRadius < part.thickness) {\n      warnings.push({\n        code: 'MIN_RADIUS',\n        message: `bend '${bend.id}' inner radius ${bend.rule.innerRadius} < thickness ${part.thickness} (R < 1×T)`,\n        featureId: bend.id,\n      });\n    }\n  }\n  return warnings;\n}\n\nfunction checkCollisions(part: SheetMetalPart): SheetMetalWarning[] {\n  const warnings: SheetMetalWarning[] = [];\n  if (part.bends.length < 2 || part.solid === undefined) return warnings;\n\n  const b = getBounds(part.solid);\n  const center: Vec3 = [(b.xMin + b.xMax) / 2, (b.yMin + b.yMax) / 2, 0];\n\n  const boxes: { id: string; bounds: Bounds3D }[] = [];\n  for (const bend of part.bends) {\n    const flange = part.flanges.find((f) => f.id === bend.id);\n    if (flange === undefined) continue;\n    // The analytic flangeBounds re-fold assumes the flange folds off the z=0 base\n    // plane: correct for root flanges, but wrong for chained flanges whose parent\n    // edge sits off that plane (it would report false-positive corner collisions).\n    // For chained flanges, use the AABB authorPart recorded from real geometry.\n    const parentId = flange.baseEdge.parentId;\n    const isChained =\n      parentId !== undefined && parentId !== ROOT_FLAT_ID && parentId !== 'face-0';\n    const bounds =\n      isChained && flange.foldedBounds !== undefined\n        ? flange.foldedBounds\n        : flangeBounds(bend, flange.length, flange.span, part.thickness, center);\n    boxes.push({ id: bend.id, bounds });\n  }\n\n  // A corner resolved by a miter or a corner relief is no longer an interference:\n  // both record a `CornerMiter` for the pair, so skip those pairs.\n  const resolved = new Set<string>();\n  for (const m of part.miters ?? []) {\n    resolved.add(pairKey(m.flangeA, m.flangeB));\n  }\n\n  for (let i = 0; i < boxes.length; i += 1) {\n    for (let j = i + 1; j < boxes.length; j += 1) {\n      const a = boxes[i];\n      const b = boxes[j];\n      if (a === undefined || b === undefined) continue;\n      if (resolved.has(pairKey(a.id, b.id))) continue;\n      if (boundsOverlap(a.bounds, b.bounds)) {\n        warnings.push({\n          code: 'COLLISION',\n          message: `flanges '${a.id}' and '${b.id}' overlap once folded`,\n          featureId: a.id,\n        });\n      }\n    }\n  }\n  return warnings;\n}\n\n/**\n * Axis-aligned bounding box of a folded flange flat, computed analytically from\n * its recorded bend feature (no kernel call). The flat is a `length × span ×\n * thickness` box that — before folding — lies in the base plane, extending\n * outward from the bend axis along the run direction. Folding up by `angleDeg`\n * rotates that run+thickness plane about the axis. The eight folded corners give\n * the AABB. This mirrors {@link authorPart}'s `rotate(-θ)` up-fold (which maps the\n * run direction toward +Z) without re-running the boolean construction.\n */\nfunction flangeBounds(\n  bend: BendFeature,\n  length: number,\n  span: number,\n  thickness: number,\n  center: Vec3\n): Bounds3D {\n  const axis = vecNormalize(bend.axisDir);\n  const run = outwardRun(bend.axisOrigin, axis, center);\n  // A down-bend folds the run toward −Z instead of +Z.\n  const up: Vec3 = bend.direction === 'down' ? [0, 0, -1] : [0, 0, 1];\n\n  const theta = (bend.angleDeg * Math.PI) / 180;\n  const cos = Math.cos(theta);\n  const sin = Math.sin(theta);\n\n  // Folding up by θ rotates the run/thickness plane about the axis: the run\n  // direction tips toward +Z, the sheet normal tips back toward −run.\n  const runFolded: Vec3 = [\n    run[0] * cos + up[0] * sin,\n    run[1] * cos + up[1] * sin,\n    run[2] * cos + up[2] * sin,\n  ];\n  const normalFolded: Vec3 = [\n    -run[0] * sin + up[0] * cos,\n    -run[1] * sin + up[1] * cos,\n    -run[2] * sin + up[2] * cos,\n  ];\n\n  const base: Vec3 = [bend.axisOrigin[0], bend.axisOrigin[1], 0];\n  const corners: Vec3[] = [];\n  for (const s of [0, span]) {\n    for (const l of [0, length]) {\n      for (const t of [0, thickness]) {\n        const p = vecAdd(\n          vecAdd(vecAdd(base, vecScale(axis, s)), vecScale(runFolded, l)),\n          vecScale(normalFolded, t)\n        );\n        corners.push(p);\n      }\n    }\n  }\n\n  let xMin = Infinity;\n  let xMax = -Infinity;\n  let yMin = Infinity;\n  let yMax = -Infinity;\n  let zMin = Infinity;\n  let zMax = -Infinity;\n  for (const c of corners) {\n    if (c[0] < xMin) xMin = c[0];\n    if (c[0] > xMax) xMax = c[0];\n    if (c[1] < yMin) yMin = c[1];\n    if (c[1] > yMax) yMax = c[1];\n    if (c[2] < zMin) zMin = c[2];\n    if (c[2] > zMax) zMax = c[2];\n  }\n  return { xMin, xMax, yMin, yMax, zMin, zMax };\n}\n\n/** In-plane perpendicular to the axis pointing away from the part center. */\nfunction outwardRun(axisOrigin: Vec3, axis: Vec3, center: Vec3): Vec3 {\n  const perp = vecNormalize(vecCross(axis, [0, 0, 1]));\n  const toEdge: Vec3 = [\n    axisOrigin[0] - center[0],\n    axisOrigin[1] - center[1],\n    0,\n  ];\n  const dot = perp[0] * toEdge[0] + perp[1] * toEdge[1];\n  return dot >= 0 ? perp : [-perp[0], -perp[1], -perp[2]];\n}\n\n/** Order-independent key for a flange pair (corner identity). */\nfunction pairKey(a: string, b: string): string {\n  return a < b ? `${a}::${b}` : `${b}::${a}`;\n}\n\nfunction boundsOverlap(a: Bounds3D, b: Bounds3D): boolean {\n  return (\n    a.xMin < b.xMax - OVERLAP_TOL &&\n    b.xMin < a.xMax - OVERLAP_TOL &&\n    a.yMin < b.yMax - OVERLAP_TOL &&\n    b.yMin < a.yMax - OVERLAP_TOL &&\n    a.zMin < b.zMax - OVERLAP_TOL &&\n    b.zMin < a.zMax - OVERLAP_TOL\n  );\n}\n"]}
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Returns a list of\n * {@link SheetMetalWarning} — these are advisory, never errors: a part with\n * warnings is still produced and exportable. Three checks per plan §6:\n *\n *  - `INVALID_SOLID`: the folded solid is missing, fails kernel validity, or has\n *    no positive volume.\n *  - `COLLISION`: two flanges' axis-aligned bounding boxes overlap once folded —\n *    the cheap interference signal for corners that need a miter or relief cut.\n *  - `MIN_RADIUS`: a bend's inner radius is below one material thickness\n *    (`R < 1×T`), the standard minimum-bend-radius rule of thumb.\n *\n * @param part - the sheet metal part to validate.\n * @returns the list of warnings (empty if valid).\n */\nexport function validatePart(part: SheetMetalPart): SheetMetalWarning[] {\n  const warnings: SheetMetalWarning[] = [];\n  warnings.push(...checkSolid(part));\n  warnings.push(...checkCollisions(part));\n  warnings.push(...checkMinRadius(part));\n  return warnings;\n}\n\nfunction checkSolid(part: SheetMetalPart): SheetMetalWarning[] {\n  const solid = part.solid;\n  if (solid === undefined) {\n    return [{ code: 'INVALID_SOLID', message: 'part has no folded solid' }];\n  }\n  if (!isValid(solid)) {\n    return [{ code: 'INVALID_SOLID', message: 'folded solid failed kernel validity check' }];\n  }\n  const vol = measureVolume(solid);\n  if (vol <= 0) {\n    return [\n      {\n        code: 'INVALID_SOLID',\n        message: `folded solid has non-positive volume ${vol}`,\n      },\n    ];\n  }\n  return [];\n}\n\nfunction checkMinRadius(part: SheetMetalPart): SheetMetalWarning[] {\n  const warnings: SheetMetalWarning[] = [];\n  if (!(part.thickness > 0)) return warnings;\n  for (const bend of part.bends) {\n    if (bend.id.startsWith('seam::')) continue;\n    if (bend.rule.innerRadius < part.thickness) {\n      warnings.push({\n        code: 'MIN_RADIUS',\n        message: `bend '${bend.id}' inner radius ${bend.rule.innerRadius} < thickness ${part.thickness} (R < 1×T)`,\n        featureId: bend.id,\n      });\n    }\n  }\n  return warnings;\n}\n\nfunction checkCollisions(part: SheetMetalPart): SheetMetalWarning[] {\n  const warnings: SheetMetalWarning[] = [];\n  if (part.bends.length < 2 || part.solid === undefined) return warnings;\n\n  const b = getBounds(part.solid);\n  const center: Vec3 = [(b.xMin + b.xMax) / 2, (b.yMin + b.yMax) / 2, 0];\n\n  const boxes: { id: string; bounds: Bounds3D }[] = [];\n  for (const bend of part.bends) {\n    const flange = part.flanges.find((f) => f.id === bend.id);\n    if (flange === undefined) continue;\n    // The analytic flangeBounds re-fold assumes the flange folds off the z=0 base\n    // plane: correct for root flanges, but wrong for chained flanges whose parent\n    // edge sits off that plane (it would report false-positive corner collisions).\n    // For chained flanges, use the AABB authorPart recorded from real geometry.\n    const parentId = flange.baseEdge.parentId;\n    const isChained =\n      parentId !== undefined && parentId !== ROOT_FLAT_ID && parentId !== 'face-0';\n    const bounds =\n      isChained && flange.foldedBounds !== undefined\n        ? flange.foldedBounds\n        : flangeBounds(bend, flange.length, flange.span, part.thickness, center);\n    boxes.push({ id: bend.id, bounds });\n  }\n\n  // A corner resolved by a miter or a corner relief is no longer an interference:\n  // both record a `CornerMiter` for the pair, so skip those pairs.\n  const resolved = new Set<string>();\n  for (const m of part.miters ?? []) {\n    resolved.add(pairKey(m.flangeA, m.flangeB));\n  }\n\n  for (let i = 0; i < boxes.length; i += 1) {\n    for (let j = i + 1; j < boxes.length; j += 1) {\n      const a = boxes[i];\n      const b = boxes[j];\n      if (a === undefined || b === undefined) continue;\n      if (resolved.has(pairKey(a.id, b.id))) continue;\n      if (boundsOverlap(a.bounds, b.bounds)) {\n        warnings.push({\n          code: 'COLLISION',\n          message: `flanges '${a.id}' and '${b.id}' overlap once folded`,\n          featureId: a.id,\n        });\n      }\n    }\n  }\n  return warnings;\n}\n\n/**\n * Axis-aligned bounding box of a folded flange flat, computed analytically from\n * its recorded bend feature (no kernel call). The flat is a `length × span ×\n * thickness` box that — before folding — lies in the base plane, extending\n * outward from the bend axis along the run direction. Folding up by `angleDeg`\n * rotates that run+thickness plane about the axis. The eight folded corners give\n * the AABB. This mirrors {@link authorPart}'s `rotate(-θ)` up-fold (which maps the\n * run direction toward +Z) without re-running the boolean construction.\n */\nfunction flangeBounds(\n  bend: BendFeature,\n  length: number,\n  span: number,\n  thickness: number,\n  center: Vec3\n): Bounds3D {\n  const axis = vecNormalize(bend.axisDir);\n  const run = outwardRun(bend.axisOrigin, axis, center);\n  // A down-bend folds the run toward −Z instead of +Z.\n  const up: Vec3 = bend.direction === 'down' ? [0, 0, -1] : [0, 0, 1];\n\n  const theta = (bend.angleDeg * Math.PI) / 180;\n  const cos = Math.cos(theta);\n  const sin = Math.sin(theta);\n\n  // Folding up by θ rotates the run/thickness plane about the axis: the run\n  // direction tips toward +Z, the sheet normal tips back toward −run.\n  const runFolded: Vec3 = [\n    run[0] * cos + up[0] * sin,\n    run[1] * cos + up[1] * sin,\n    run[2] * cos + up[2] * sin,\n  ];\n  const normalFolded: Vec3 = [\n    -run[0] * sin + up[0] * cos,\n    -run[1] * sin + up[1] * cos,\n    -run[2] * sin + up[2] * cos,\n  ];\n\n  const base: Vec3 = [bend.axisOrigin[0], bend.axisOrigin[1], 0];\n  const corners: Vec3[] = [];\n  for (const s of [0, span]) {\n    for (const l of [0, length]) {\n      for (const t of [0, thickness]) {\n        const p = vecAdd(\n          vecAdd(vecAdd(base, vecScale(axis, s)), vecScale(runFolded, l)),\n          vecScale(normalFolded, t)\n        );\n        corners.push(p);\n      }\n    }\n  }\n\n  let xMin = Infinity;\n  let xMax = -Infinity;\n  let yMin = Infinity;\n  let yMax = -Infinity;\n  let zMin = Infinity;\n  let zMax = -Infinity;\n  for (const c of corners) {\n    if (c[0] < xMin) xMin = c[0];\n    if (c[0] > xMax) xMax = c[0];\n    if (c[1] < yMin) yMin = c[1];\n    if (c[1] > yMax) yMax = c[1];\n    if (c[2] < zMin) zMin = c[2];\n    if (c[2] > zMax) zMax = c[2];\n  }\n  return { xMin, xMax, yMin, yMax, zMin, zMax };\n}\n\n/** In-plane perpendicular to the axis pointing away from the part center. */\nfunction outwardRun(axisOrigin: Vec3, axis: Vec3, center: Vec3): Vec3 {\n  const perp = vecNormalize(vecCross(axis, [0, 0, 1]));\n  const toEdge: Vec3 = [\n    axisOrigin[0] - center[0],\n    axisOrigin[1] - center[1],\n    0,\n  ];\n  const dot = perp[0] * toEdge[0] + perp[1] * toEdge[1];\n  return dot >= 0 ? perp : [-perp[0], -perp[1], -perp[2]];\n}\n\n/** Order-independent key for a flange pair (corner identity). */\nfunction pairKey(a: string, b: string): string {\n  return a < b ? `${a}::${b}` : `${b}::${a}`;\n}\n\nfunction boundsOverlap(a: Bounds3D, b: Bounds3D): boolean {\n  return (\n    a.xMin < b.xMax - OVERLAP_TOL &&\n    b.xMin < a.xMax - OVERLAP_TOL &&\n    a.yMin < b.yMax - OVERLAP_TOL &&\n    b.yMin < a.yMax - OVERLAP_TOL &&\n    a.zMin < b.zMax - OVERLAP_TOL &&\n    b.zMin < a.zMax - OVERLAP_TOL\n  );\n}\n"]}

package/package.json

@@ -1,6 +1,6 @@
 {
   "name": "@faicad/sheetmetal",
-  "version": "0.16.1",
+  "version": "0.18.0",
   "description": "Sheet-metal CAD domain for faijs — flange authoring, fold/unfold flat patterns (ported from brepjs-sheetmetal)",
   "keywords": [
     "sheet-metal",
@@ -30,7 +30,7 @@
   ],
   "dependencies": {},
   "peerDependencies": {
-    "@faicad/faijs": "^0.16.0"
+    "@faicad/faijs": "^0.18.0"
   },
   "devDependencies": {
     "typescript": "*",