@gridspace/raster-path 1.0.4 → 1.0.6

package/src/core/path-planar.js

@@ -0,0 +1,788 @@
+/**
+ * ═══════════════════════════════════════════════════════════════════════════
+ * Path Planar - Planar Toolpath Generation
+ * ═══════════════════════════════════════════════════════════════════════════
+ *
+ * Generates CNC toolpaths by scanning a sparse tool representation over a
+ * dense terrain height map. Computes Z-heights where tool contacts terrain.
+ *
+ * EXPORTS:
+ * ────────
+ * Functions:
+ *   - generateToolpath(terrainPoints, toolPoints, xStep, yStep, zFloor, ...)
+ *       Main API - generates toolpath with automatic tiling
+ *   - generateToolpathWithSparseTools(terrainPoints, sparseToolData, ...)
+ *       Batch-optimized version with pre-created sparse tool
+ *   - createReusableToolpathBuffers(width, height, sparseToolData, ...)
+ *       Create GPU buffers for reuse across multiple tiles
+ *   - destroyReusableToolpathBuffers(buffers)
+ *       Cleanup GPU buffers
+ *   - runToolpathComputeWithBuffers(terrainData, ...)
+ *       Run toolpath compute shader with pre-allocated buffers
+ *
+ * ALGORITHM:
+ * ──────────
+ * For each output point (i, j) sampled at (xStep, yStep):
+ *   1. Position tool center at terrain grid cell (i, j)
+ *   2. For each point in sparse tool:
+ *      - Calculate terrain sample position: terrain[i + xOffset, j + yOffset]
+ *      - Calculate tool collision Z: terrainZ - toolZ
+ *   3. Output maximum collision Z (highest point tool must be raised)
+ *
+ * TILING SUPPORT:
+ * ───────────────
+ * For large terrains exceeding GPU memory:
+ * 1. Calculate tool dimensions to determine required overlap
+ * 2. Subdivide terrain into tiles with tool-radius overlap
+ * 3. Pre-generate all tile terrain arrays (CPU side)
+ * 4. Create reusable GPU buffers sized for largest tile
+ * 5. Process each tile, reusing buffers
+ * 6. Stitch results, dropping overlap regions
+ *
+ * MEMORY OPTIMIZATION:
+ * ────────────────────
+ * - Tool buffer created once, reused for all tiles
+ * - Terrain buffer updated per tile (GPU DMA)
+ * - Output buffer reused, read back per tile
+ * - Reduces GPU memory pressure by 10-100x for large models
+ *
+ * OUTPUT FORMAT:
+ * ──────────────
+ * Float32Array of Z-heights, row-major order:
+ *   [z(0,0), z(1,0), z(2,0), ..., z(0,1), z(1,1), ...]
+ * Dimensions: (terrain.width / xStep) × (terrain.height / yStep)
+ *
+ * ═══════════════════════════════════════════════════════════════════════════
+ */
+
+import {
+    device, deviceCapabilities, isInitialized, config,
+    cachedToolpathPipeline, EMPTY_CELL, debug, initWebGPU
+} from './raster-config.js';
+import { createHeightMapFromPoints } from './raster-planar.js';
+import { createSparseToolFromPoints } from './raster-tool.js';
+
+// Generate toolpath with pre-created sparse tool (for batch operations)
+export async function generateToolpathWithSparseTools(terrainPoints, sparseToolData, xStep, yStep, oobZ, gridStep, terrainBounds = null, singleScanline = false) {
+    const startTime = performance.now();
+
+    try {
+        // Create height map from terrain points (use terrain bounds if provided)
+        const terrainMapData = createHeightMapFromPoints(terrainPoints, gridStep, terrainBounds);
+
+        // Run WebGPU compute with pre-created sparse tool
+        const result = await runToolpathCompute(
+            terrainMapData, sparseToolData, xStep, yStep, oobZ, startTime
+        );
+
+        return result;
+    } catch (error) {
+        debug.error('Error generating toolpath:', error);
+        throw error;
+    }
+}
+
+// Generate toolpath for a single region (internal)
+async function generateToolpathSingle(terrainPoints, toolPoints, xStep, yStep, oobZ, gridStep, terrainBounds = null) {
+    const startTime = performance.now();
+    debug.log('Generating toolpath...');
+    debug.log(`Input: terrain ${terrainPoints.length/3} points, tool ${toolPoints.length/3} points, steps (${xStep}, ${yStep}), oobZ ${oobZ}, gridStep ${gridStep}`);
+
+    if (terrainBounds) {
+        debug.log(`Using terrain bounds: min(${terrainBounds.min.x.toFixed(2)}, ${terrainBounds.min.y.toFixed(2)}, ${terrainBounds.min.z.toFixed(2)}) max(${terrainBounds.max.x.toFixed(2)}, ${terrainBounds.max.y.toFixed(2)}, ${terrainBounds.max.z.toFixed(2)})`);
+    }
+
+    try {
+        // Create height map from terrain points (use terrain bounds if provided)
+        const terrainMapData = createHeightMapFromPoints(terrainPoints, gridStep, terrainBounds);
+        debug.log(`Created terrain map: ${terrainMapData.width}x${terrainMapData.height}`);
+
+        // Create sparse tool representation
+        const sparseToolData = createSparseToolFromPoints(toolPoints);
+        debug.log(`Created sparse tool: ${sparseToolData.count} points`);
+
+        // Run WebGPU compute
+        const result = await runToolpathCompute(
+            terrainMapData, sparseToolData, xStep, yStep, oobZ, startTime
+        );
+
+        return result;
+    } catch (error) {
+        debug.error('Error generating toolpath:', error);
+        throw error;
+    }
+}
+
+async function runToolpathCompute(terrainMapData, sparseToolData, xStep, yStep, oobZ, startTime) {
+    if (!isInitialized) {
+        const success = await initWebGPU();
+        if (!success) {
+            throw new Error('WebGPU not available');
+        }
+    }
+
+    // Use WASM-generated terrain grid
+    const terrainBuffer = device.createBuffer({
+        size: terrainMapData.grid.byteLength,
+        usage: GPUBufferUsage.STORAGE | GPUBufferUsage.COPY_DST,
+    });
+    device.queue.writeBuffer(terrainBuffer, 0, terrainMapData.grid);
+
+    // Use WASM-generated sparse tool
+    const toolBufferData = new ArrayBuffer(sparseToolData.count * 16);
+    const toolBufferI32 = new Int32Array(toolBufferData);
+    const toolBufferF32 = new Float32Array(toolBufferData);
+
+    for (let i = 0; i < sparseToolData.count; i++) {
+        toolBufferI32[i * 4 + 0] = sparseToolData.xOffsets[i];
+        toolBufferI32[i * 4 + 1] = sparseToolData.yOffsets[i];
+        toolBufferF32[i * 4 + 2] = sparseToolData.zValues[i];
+        toolBufferF32[i * 4 + 3] = 0;
+    }
+
+    const toolBuffer = device.createBuffer({
+        size: toolBufferData.byteLength,
+        usage: GPUBufferUsage.STORAGE | GPUBufferUsage.COPY_DST,
+    });
+    device.queue.writeBuffer(toolBuffer, 0, toolBufferData);
+
+    // Calculate output dimensions
+    const pointsPerLine = Math.ceil(terrainMapData.width / xStep);
+    const numScanlines = Math.ceil(terrainMapData.height / yStep);
+    const outputSize = pointsPerLine * numScanlines;
+
+    const outputBuffer = device.createBuffer({
+        size: outputSize * 4,
+        usage: GPUBufferUsage.STORAGE | GPUBufferUsage.COPY_SRC,
+    });
+
+    const uniformData = new Uint32Array([
+        terrainMapData.width,
+        terrainMapData.height,
+        sparseToolData.count,
+        xStep,
+        yStep,
+        0,
+        pointsPerLine,
+        numScanlines,
+        0,  // y_offset (default 0 for planar mode)
+    ]);
+    const uniformDataFloat = new Float32Array(uniformData.buffer);
+    uniformDataFloat[5] = oobZ;
+
+    const uniformBuffer = device.createBuffer({
+        size: uniformData.byteLength,
+        usage: GPUBufferUsage.UNIFORM | GPUBufferUsage.COPY_DST,
+    });
+    device.queue.writeBuffer(uniformBuffer, 0, uniformData);
+
+    // CRITICAL: Wait for all writeBuffer operations to complete before compute dispatch
+    await device.queue.onSubmittedWorkDone();
+
+    // Use cached pipeline
+    const bindGroup = device.createBindGroup({
+        layout: cachedToolpathPipeline.getBindGroupLayout(0),
+        entries: [
+            { binding: 0, resource: { buffer: terrainBuffer } },
+            { binding: 1, resource: { buffer: toolBuffer } },
+            { binding: 2, resource: { buffer: outputBuffer } },
+            { binding: 3, resource: { buffer: uniformBuffer } },
+        ],
+    });
+
+    const commandEncoder = device.createCommandEncoder();
+    const passEncoder = commandEncoder.beginComputePass();
+    passEncoder.setPipeline(cachedToolpathPipeline);
+    passEncoder.setBindGroup(0, bindGroup);
+
+    const workgroupsX = Math.ceil(pointsPerLine / 16);
+    const workgroupsY = Math.ceil(numScanlines / 16);
+    passEncoder.dispatchWorkgroups(workgroupsX, workgroupsY);
+    passEncoder.end();
+
+    const stagingBuffer = device.createBuffer({
+        size: outputSize * 4,
+        usage: GPUBufferUsage.MAP_READ | GPUBufferUsage.COPY_DST,
+    });
+
+    commandEncoder.copyBufferToBuffer(outputBuffer, 0, stagingBuffer, 0, outputSize * 4);
+
+    device.queue.submit([commandEncoder.finish()]);
+
+    // CRITICAL: Wait for GPU to finish before reading results
+    await device.queue.onSubmittedWorkDone();
+
+    await stagingBuffer.mapAsync(GPUMapMode.READ);
+
+    const outputData = new Float32Array(stagingBuffer.getMappedRange());
+    const result = new Float32Array(outputData);
+    stagingBuffer.unmap();
+
+    terrainBuffer.destroy();
+    toolBuffer.destroy();
+    outputBuffer.destroy();
+    uniformBuffer.destroy();
+    stagingBuffer.destroy();
+
+    const endTime = performance.now();
+
+    return {
+        pathData: result,
+        numScanlines,
+        pointsPerLine,
+        generationTime: endTime - startTime
+    };
+}
+
+// Create reusable GPU buffers for tiled toolpath generation
+export function createReusableToolpathBuffers(terrainWidth, terrainHeight, sparseToolData, xStep, yStep) {
+    const pointsPerLine = Math.ceil(terrainWidth / xStep);
+    const numScanlines = Math.ceil(terrainHeight / yStep);
+    const outputSize = pointsPerLine * numScanlines;
+
+    // Create terrain buffer (will be updated for each tile)
+    const terrainBuffer = device.createBuffer({
+        size: terrainWidth * terrainHeight * 4,
+        usage: GPUBufferUsage.STORAGE | GPUBufferUsage.COPY_DST,
+    });
+
+    // Create tool buffer (STATIC - same for all tiles!)
+    const toolBufferData = new ArrayBuffer(sparseToolData.count * 16);
+    const toolBufferI32 = new Int32Array(toolBufferData);
+    const toolBufferF32 = new Float32Array(toolBufferData);
+
+    for (let i = 0; i < sparseToolData.count; i++) {
+        toolBufferI32[i * 4 + 0] = sparseToolData.xOffsets[i];
+        toolBufferI32[i * 4 + 1] = sparseToolData.yOffsets[i];
+        toolBufferF32[i * 4 + 2] = sparseToolData.zValues[i];
+        toolBufferF32[i * 4 + 3] = 0;
+    }
+
+    const toolBuffer = device.createBuffer({
+        size: toolBufferData.byteLength,
+        usage: GPUBufferUsage.STORAGE | GPUBufferUsage.COPY_DST,
+    });
+    device.queue.writeBuffer(toolBuffer, 0, toolBufferData);  // Write once!
+
+    // Create output buffer (will be read for each tile)
+    const outputBuffer = device.createBuffer({
+        size: outputSize * 4,
+        usage: GPUBufferUsage.STORAGE | GPUBufferUsage.COPY_SRC,
+    });
+
+    // Create uniform buffer (will be updated for each tile)
+    const uniformBuffer = device.createBuffer({
+        size: 36,  // 9 fields × 4 bytes (added y_offset field)
+        usage: GPUBufferUsage.UNIFORM | GPUBufferUsage.COPY_DST,
+    });
+
+    // Create staging buffer (will be reused for readback)
+    const stagingBuffer = device.createBuffer({
+        size: outputSize * 4,
+        usage: GPUBufferUsage.MAP_READ | GPUBufferUsage.COPY_DST,
+    });
+
+    return {
+        terrainBuffer,
+        toolBuffer,
+        outputBuffer,
+        uniformBuffer,
+        stagingBuffer,
+        maxOutputSize: outputSize,
+        maxTerrainWidth: terrainWidth,
+        maxTerrainHeight: terrainHeight,
+        sparseToolData
+    };
+}
+
+// Destroy reusable GPU buffers
+export function destroyReusableToolpathBuffers(buffers) {
+    buffers.terrainBuffer.destroy();
+    buffers.toolBuffer.destroy();
+    buffers.outputBuffer.destroy();
+    buffers.uniformBuffer.destroy();
+    buffers.stagingBuffer.destroy();
+}
+
+// Run toolpath compute using pre-created reusable buffers
+export async function runToolpathComputeWithBuffers(terrainData, terrainWidth, terrainHeight, xStep, yStep, oobZ, buffers, startTime) {
+    // Update terrain buffer with new tile data
+    device.queue.writeBuffer(buffers.terrainBuffer, 0, terrainData);
+
+    // Calculate output dimensions
+    const pointsPerLine = Math.ceil(terrainWidth / xStep);
+    const numScanlines = Math.ceil(terrainHeight / yStep);
+    const outputSize = pointsPerLine * numScanlines;
+
+    // Calculate Y offset for single-scanline radial mode
+    // When numScanlines=1 and terrainHeight > 1, center the tool at the midline
+    const yOffset = (numScanlines === 1 && terrainHeight > 1) ? Math.floor(terrainHeight / 2) : 0;
+
+    // Update uniforms for this tile
+    const uniformData = new Uint32Array([
+        terrainWidth,
+        terrainHeight,
+        buffers.sparseToolData.count,
+        xStep,
+        yStep,
+        0,
+        pointsPerLine,
+        numScanlines,
+        yOffset,  // y_offset for radial single-scanline mode
+    ]);
+    const uniformDataFloat = new Float32Array(uniformData.buffer);
+    uniformDataFloat[5] = oobZ;
+    device.queue.writeBuffer(buffers.uniformBuffer, 0, uniformData);
+
+    // CRITICAL: Wait for all writeBuffer operations to complete before compute dispatch
+    // Without this, compute shader may read stale/incomplete buffer data
+    await device.queue.onSubmittedWorkDone();
+
+    // Create bind group (reusing cached pipeline)
+    const bindGroup = device.createBindGroup({
+        layout: cachedToolpathPipeline.getBindGroupLayout(0),
+        entries: [
+            { binding: 0, resource: { buffer: buffers.terrainBuffer } },
+            { binding: 1, resource: { buffer: buffers.toolBuffer } },
+            { binding: 2, resource: { buffer: buffers.outputBuffer } },
+            { binding: 3, resource: { buffer: buffers.uniformBuffer } },
+        ],
+    });
+
+    // Dispatch compute shader
+    const commandEncoder = device.createCommandEncoder();
+    const passEncoder = commandEncoder.beginComputePass();
+    passEncoder.setPipeline(cachedToolpathPipeline);
+    passEncoder.setBindGroup(0, bindGroup);
+
+    const workgroupsX = Math.ceil(pointsPerLine / 16);
+    const workgroupsY = Math.ceil(numScanlines / 16);
+    passEncoder.dispatchWorkgroups(workgroupsX, workgroupsY);
+    passEncoder.end();
+
+    // Copy to staging buffer
+    commandEncoder.copyBufferToBuffer(buffers.outputBuffer, 0, buffers.stagingBuffer, 0, outputSize * 4);
+
+    device.queue.submit([commandEncoder.finish()]);
+
+    // CRITICAL: Wait for GPU to finish before reading results
+    await device.queue.onSubmittedWorkDone();
+
+    await buffers.stagingBuffer.mapAsync(GPUMapMode.READ);
+
+    // Create a true copy using slice() - new Float32Array(typedArray) only creates a view!
+    const outputData = new Float32Array(buffers.stagingBuffer.getMappedRange(), 0, outputSize);
+    const result = outputData.slice();  // slice() creates a new ArrayBuffer with copied data
+    buffers.stagingBuffer.unmap();
+
+    const endTime = performance.now();
+
+    // Debug: Log first few Z values to detect non-determinism
+    if (result.length > 0) {
+        const samples = [];
+        for (let i = 0; i < Math.min(10, result.length); i++) {
+            samples.push(result[i].toFixed(3));
+        }
+        // debug.log(`[Toolpath] Output samples (${result.length} total): ${samples.join(', ')}`);
+    }
+
+    return {
+        pathData: result,
+        numScanlines,
+        pointsPerLine,
+        generationTime: endTime - startTime
+    };
+}
+
+// Generate toolpath with tiling support (public API)
+export async function generateToolpath(terrainPoints, toolPoints, xStep, yStep, oobZ, gridStep, terrainBounds = null, singleScanline = false) {
+    // Calculate bounds if not provided
+    if (!terrainBounds) {
+        let minX = Infinity, minY = Infinity, minZ = Infinity;
+        let maxX = -Infinity, maxY = -Infinity, maxZ = -Infinity;
+        for (let i = 0; i < terrainPoints.length; i += 3) {
+            minX = Math.min(minX, terrainPoints[i]);
+            maxX = Math.max(maxX, terrainPoints[i]);
+            minY = Math.min(minY, terrainPoints[i + 1]);
+            maxY = Math.max(maxY, terrainPoints[i + 1]);
+            minZ = Math.min(minZ, terrainPoints[i + 2]);
+            maxZ = Math.max(maxZ, terrainPoints[i + 2]);
+        }
+        terrainBounds = {
+            min: { x: minX, y: minY, z: minZ },
+            max: { x: maxX, y: maxY, z: maxZ }
+        };
+    }
+
+    // Note: singleScanline mode means OUTPUT only centerline, but terrain bounds stay full
+    // This ensures all terrain Y values contribute to tool interference at the centerline
+
+    // Debug tool bounds and center
+    for (let i=0; i<toolPoints.length; i += 3) {
+        if (toolPoints[i] === 0 && toolPoints[i+1] === 0) {
+            debug.log('[WebGPU Worker]', { TOOL_CENTER: toolPoints[i+2] });
+        }
+    }
+    debug.log('[WebGPU Worker]',
+        'toolZMin:', ([...toolPoints].filter((_,i) => i % 3 === 2).reduce((a,b) => Math.min(a,b), Infinity)),
+        'toolZMax:', ([...toolPoints].filter((_,i) => i % 3 === 2).reduce((a,b) => Math.max(a,b), -Infinity))
+    );
+
+    // Calculate tool dimensions for overlap
+    // Tool points are [gridX, gridY, Z] where X/Y are grid indices (not mm)
+    let toolMinX = Infinity, toolMaxX = -Infinity;
+    let toolMinY = Infinity, toolMaxY = -Infinity;
+    for (let i = 0; i < toolPoints.length; i += 3) {
+        toolMinX = Math.min(toolMinX, toolPoints[i]);
+        toolMaxX = Math.max(toolMaxX, toolPoints[i]);
+        toolMinY = Math.min(toolMinY, toolPoints[i + 1]);
+        toolMaxY = Math.max(toolMaxY, toolPoints[i + 1]);
+    }
+    // Tool dimensions in grid cells
+    const toolWidthCells = toolMaxX - toolMinX;
+    const toolHeightCells = toolMaxY - toolMinY;
+    // Convert to mm for logging
+    const toolWidthMm = toolWidthCells * gridStep;
+    const toolHeightMm = toolHeightCells * gridStep;
+
+    // Check if tiling is needed based on output grid size
+    const outputWidth = Math.ceil((terrainBounds.max.x - terrainBounds.min.x) / gridStep) + 1;
+    const outputHeight = Math.ceil((terrainBounds.max.y - terrainBounds.min.y) / gridStep) + 1;
+    const outputPoints = Math.ceil(outputWidth / xStep) * Math.ceil(outputHeight / yStep);
+    const outputMemory = outputPoints * 4; // 4 bytes per float
+
+    const configuredLimit = config.maxGPUMemoryMB * 1024 * 1024;
+    const deviceLimit = deviceCapabilities.maxStorageBufferBindingSize;
+    const maxSafeSize = Math.min(configuredLimit, deviceLimit) * config.gpuMemorySafetyMargin;
+
+    if (outputMemory <= maxSafeSize) {
+        // No tiling needed
+        return await generateToolpathSingle(terrainPoints, toolPoints, xStep, yStep, oobZ, gridStep, terrainBounds);
+    }
+
+    // Tiling needed (terrain is ALWAYS dense)
+    const tilingStartTime = performance.now();
+    debug.log('Using tiled toolpath generation');
+    debug.log(`Terrain: DENSE (${terrainPoints.length} cells = ${outputWidth}x${outputHeight})`);
+    debug.log(`Tool dimensions: ${toolWidthMm.toFixed(2)}mm × ${toolHeightMm.toFixed(2)}mm (${toolWidthCells}×${toolHeightCells} cells)`);
+
+    // Create tiles with tool-size overlap (pass dimensions in grid cells)
+    const { tiles, maxTileGridWidth, maxTileGridHeight } = createToolpathTiles(terrainBounds, gridStep, xStep, yStep, toolWidthCells, toolHeightCells, maxSafeSize);
+    debug.log(`Created ${tiles.length} tiles`);
+
+    // Pre-generate all tile terrain point arrays
+    const pregenStartTime = performance.now();
+    debug.log(`Pre-generating ${tiles.length} tile terrain arrays...`);
+    const allTileTerrainPoints = [];
+
+    for (let i = 0; i < tiles.length; i++) {
+        const tile = tiles[i];
+
+        // Extract terrain sub-grid for this tile (terrain is ALWAYS dense)
+        const tileMinGridX = Math.floor((tile.bounds.min.x - terrainBounds.min.x) / gridStep);
+        const tileMaxGridX = Math.ceil((tile.bounds.max.x - terrainBounds.min.x) / gridStep);
+        const tileMinGridY = Math.floor((tile.bounds.min.y - terrainBounds.min.y) / gridStep);
+        const tileMaxGridY = Math.ceil((tile.bounds.max.y - terrainBounds.min.y) / gridStep);
+
+        const tileWidth = tileMaxGridX - tileMinGridX + 1;
+        const tileHeight = tileMaxGridY - tileMinGridY + 1;
+
+        // Pad to max dimensions for consistent buffer sizing
+        const paddedTileTerrainPoints = new Float32Array(maxTileGridWidth * maxTileGridHeight);
+        paddedTileTerrainPoints.fill(EMPTY_CELL);
+
+        // Copy relevant sub-grid from full terrain into top-left of padded array
+        for (let ty = 0; ty < tileHeight; ty++) {
+            const globalY = tileMinGridY + ty;
+            if (globalY < 0 || globalY >= outputHeight) continue;
+
+            for (let tx = 0; tx < tileWidth; tx++) {
+                const globalX = tileMinGridX + tx;
+                if (globalX < 0 || globalX >= outputWidth) continue;
+
+                const globalIdx = globalY * outputWidth + globalX;
+                const tileIdx = ty * maxTileGridWidth + tx;  // Use maxTileGridWidth for stride
+                paddedTileTerrainPoints[tileIdx] = terrainPoints[globalIdx];
+            }
+        }
+
+        allTileTerrainPoints.push({
+            data: paddedTileTerrainPoints,
+            actualWidth: tileWidth,
+            actualHeight: tileHeight
+        });
+    }
+
+    const pregenTime = performance.now() - pregenStartTime;
+    debug.log(`Pre-generation complete in ${pregenTime.toFixed(1)}ms`);
+
+    // Create reusable GPU buffers (sized for maximum tile)
+    if (!isInitialized) {
+        const success = await initWebGPU();
+        if (!success) {
+            throw new Error('WebGPU not available');
+        }
+    }
+
+    const sparseToolData = createSparseToolFromPoints(toolPoints);
+    const reusableBuffers = createReusableToolpathBuffers(maxTileGridWidth, maxTileGridHeight, sparseToolData, xStep, yStep);
+    debug.log(`Created reusable GPU buffers for ${maxTileGridWidth}x${maxTileGridHeight} tiles`);
+
+    // Process each tile with reusable buffers
+    const tileResults = [];
+    let totalTileTime = 0;
+    for (let i = 0; i < tiles.length; i++) {
+        const tile = tiles[i];
+        const tileStartTime = performance.now();
+        debug.log(`Processing tile ${i + 1}/${tiles.length}...`);
+
+        // Report progress
+        const percent = Math.round(((i + 1) / tiles.length) * 100);
+        self.postMessage({
+            type: 'toolpath-progress',
+            data: {
+                percent,
+                current: i + 1,
+                total: tiles.length,
+                layer: i + 1  // Using tile index as "layer" for consistency
+            }
+        });
+
+        debug.log(`Tile ${i+1} using pre-generated terrain: ${allTileTerrainPoints[i].actualWidth}x${allTileTerrainPoints[i].actualHeight} (padded to ${maxTileGridWidth}x${maxTileGridHeight})`);
+
+        // Generate toolpath for this tile using reusable buffers
+        const tileToolpathResult = await runToolpathComputeWithBuffers(
+            allTileTerrainPoints[i].data,
+            maxTileGridWidth,
+            maxTileGridHeight,
+            xStep,
+            yStep,
+            oobZ,
+            reusableBuffers,
+            tileStartTime
+        );
+
+        const tileTime = performance.now() - tileStartTime;
+        totalTileTime += tileTime;
+
+        tileResults.push({
+            pathData: tileToolpathResult.pathData,
+            numScanlines: tileToolpathResult.numScanlines,
+            pointsPerLine: tileToolpathResult.pointsPerLine,
+            tile: tile
+        });
+
+        debug.log(`Tile ${i + 1}/${tiles.length} complete: ${tileToolpathResult.numScanlines}×${tileToolpathResult.pointsPerLine} in ${tileTime.toFixed(1)}ms`);
+    }
+
+    // Cleanup reusable buffers
+    destroyReusableToolpathBuffers(reusableBuffers);
+
+    debug.log(`All tiles processed in ${totalTileTime.toFixed(1)}ms (avg ${(totalTileTime/tiles.length).toFixed(1)}ms per tile)`);
+
+    // Stitch tiles together, dropping overlap regions
+    const stitchStartTime = performance.now();
+    const stitchedResult = stitchToolpathTiles(tileResults, terrainBounds, gridStep, xStep, yStep);
+    const stitchTime = performance.now() - stitchStartTime;
+
+    const totalTime = performance.now() - tilingStartTime;
+    debug.log(`Stitching took ${stitchTime.toFixed(1)}ms`);
+    debug.log(`Tiled toolpath complete: ${stitchedResult.numScanlines}×${stitchedResult.pointsPerLine} in ${totalTime.toFixed(1)}ms total`);
+
+    // Update generation time to reflect total tiled time
+    stitchedResult.generationTime = totalTime;
+
+    return stitchedResult;
+}
+
+// Create tiles for toolpath generation with overlap (using integer grid coordinates)
+// toolWidth and toolHeight are in grid cells (not mm)
+function createToolpathTiles(bounds, gridStep, xStep, yStep, toolWidthCells, toolHeightCells, maxMemoryBytes) {
+    // Calculate global grid dimensions
+    const globalGridWidth = Math.ceil((bounds.max.x - bounds.min.x) / gridStep) + 1;
+    const globalGridHeight = Math.ceil((bounds.max.y - bounds.min.y) / gridStep) + 1;
+
+    // Calculate tool overlap in grid cells (use radius = half diameter)
+    // Tool centered at tile boundary needs terrain extending half tool width beyond boundary
+    const toolOverlapX = Math.ceil(toolWidthCells / 2);
+    const toolOverlapY = Math.ceil(toolHeightCells / 2);
+
+    // Binary search for optimal tile size in grid cells
+    let low = Math.max(toolOverlapX, toolOverlapY) * 2; // At least 2x tool size
+    let high = Math.max(globalGridWidth, globalGridHeight);
+    let bestTileGridSize = high;
+
+    while (low <= high) {
+        const mid = Math.floor((low + high) / 2);
+        const outputW = Math.ceil(mid / xStep);
+        const outputH = Math.ceil(mid / yStep);
+        const memoryNeeded = outputW * outputH * 4;
+
+        if (memoryNeeded <= maxMemoryBytes) {
+            bestTileGridSize = mid;
+            low = mid + 1;
+        } else {
+            high = mid - 1;
+        }
+    }
+
+    const tilesX = Math.ceil(globalGridWidth / bestTileGridSize);
+    const tilesY = Math.ceil(globalGridHeight / bestTileGridSize);
+    const coreGridWidth = Math.ceil(globalGridWidth / tilesX);
+    const coreGridHeight = Math.ceil(globalGridHeight / tilesY);
+
+    // Calculate maximum tile dimensions (for buffer sizing)
+    const maxTileGridWidth = coreGridWidth + 2 * toolOverlapX;
+    const maxTileGridHeight = coreGridHeight + 2 * toolOverlapY;
+
+    debug.log(`Creating ${tilesX}×${tilesY} tiles (${coreGridWidth}×${coreGridHeight} cells core + ${toolOverlapX}×${toolOverlapY} cells overlap)`);
+    debug.log(`Max tile dimensions: ${maxTileGridWidth}×${maxTileGridHeight} cells (for buffer sizing)`);
+
+    const tiles = [];
+    for (let ty = 0; ty < tilesY; ty++) {
+        for (let tx = 0; tx < tilesX; tx++) {
+            // Core tile in grid coordinates
+            const coreGridStartX = tx * coreGridWidth;
+            const coreGridStartY = ty * coreGridHeight;
+            const coreGridEndX = Math.min((tx + 1) * coreGridWidth, globalGridWidth) - 1;
+            const coreGridEndY = Math.min((ty + 1) * coreGridHeight, globalGridHeight) - 1;
+
+            // Extended tile with overlap in grid coordinates
+            let extGridStartX = coreGridStartX;
+            let extGridStartY = coreGridStartY;
+            let extGridEndX = coreGridEndX;
+            let extGridEndY = coreGridEndY;
+
+            // Add overlap on sides that aren't at global boundary
+            if (tx > 0) extGridStartX -= toolOverlapX;
+            if (ty > 0) extGridStartY -= toolOverlapY;
+            if (tx < tilesX - 1) extGridEndX += toolOverlapX;
+            if (ty < tilesY - 1) extGridEndY += toolOverlapY;
+
+            // Clamp to global bounds
+            extGridStartX = Math.max(0, extGridStartX);
+            extGridStartY = Math.max(0, extGridStartY);
+            extGridEndX = Math.min(globalGridWidth - 1, extGridEndX);
+            extGridEndY = Math.min(globalGridHeight - 1, extGridEndY);
+
+            // Calculate actual dimensions for this tile
+            const tileGridWidth = extGridEndX - extGridStartX + 1;
+            const tileGridHeight = extGridEndY - extGridStartY + 1;
+
+            // Convert grid coordinates to world coordinates
+            const extMinX = bounds.min.x + extGridStartX * gridStep;
+            const extMinY = bounds.min.y + extGridStartY * gridStep;
+            const extMaxX = bounds.min.x + extGridEndX * gridStep;
+            const extMaxY = bounds.min.y + extGridEndY * gridStep;
+
+            const coreMinX = bounds.min.x + coreGridStartX * gridStep;
+            const coreMinY = bounds.min.y + coreGridStartY * gridStep;
+            const coreMaxX = bounds.min.x + coreGridEndX * gridStep;
+            const coreMaxY = bounds.min.y + coreGridEndY * gridStep;
+
+            tiles.push({
+                id: `tile_${tx}_${ty}`,
+                tx, ty,
+                tilesX, tilesY,
+                gridWidth: tileGridWidth,
+                gridHeight: tileGridHeight,
+                bounds: {
+                    min: { x: extMinX, y: extMinY, z: bounds.min.z },
+                    max: { x: extMaxX, y: extMaxY, z: bounds.max.z }
+                },
+                core: {
+                    gridStart: { x: coreGridStartX, y: coreGridStartY },
+                    gridEnd: { x: coreGridEndX, y: coreGridEndY },
+                    min: { x: coreMinX, y: coreMinY },
+                    max: { x: coreMaxX, y: coreMaxY }
+                }
+            });
+        }
+    }
+
+    return { tiles, maxTileGridWidth, maxTileGridHeight };
+}
+
+// Stitch toolpath tiles together, dropping overlap regions (using integer grid coordinates)
+function stitchToolpathTiles(tileResults, globalBounds, gridStep, xStep, yStep) {
+    // Calculate global output dimensions
+    const globalWidth = Math.ceil((globalBounds.max.x - globalBounds.min.x) / gridStep) + 1;
+    const globalHeight = Math.ceil((globalBounds.max.y - globalBounds.min.y) / gridStep) + 1;
+    const globalPointsPerLine = Math.ceil(globalWidth / xStep);
+    const globalNumScanlines = Math.ceil(globalHeight / yStep);
+
+    debug.log(`Stitching toolpath: global grid ${globalWidth}x${globalHeight}, output ${globalPointsPerLine}x${globalNumScanlines}`);
+
+    const result = new Float32Array(globalPointsPerLine * globalNumScanlines);
+    result.fill(NaN);
+
+    // Fast path for 1x1 stepping: use bulk row copying
+    const use1x1FastPath = (xStep === 1 && yStep === 1);
+
+    for (const tileResult of tileResults) {
+        const tile = tileResult.tile;
+        const tileData = tileResult.pathData;
+
+        // Use the pre-calculated integer grid coordinates from tile.core
+        const coreGridStartX = tile.core.gridStart.x;
+        const coreGridStartY = tile.core.gridStart.y;
+        const coreGridEndX = tile.core.gridEnd.x;
+        const coreGridEndY = tile.core.gridEnd.y;
+
+        // Calculate tile's extended grid coordinates
+        const extGridStartX = Math.round((tile.bounds.min.x - globalBounds.min.x) / gridStep);
+        const extGridStartY = Math.round((tile.bounds.min.y - globalBounds.min.y) / gridStep);
+
+        let copiedCount = 0;
+
+        // Calculate output coordinate ranges for this tile's core
+        // Core region in grid coordinates
+        const coreGridWidth = coreGridEndX - coreGridStartX + 1;
+        const coreGridHeight = coreGridEndY - coreGridStartY + 1;
+
+        // Core region in output coordinates (sampled by xStep/yStep)
+        const coreOutStartX = Math.floor(coreGridStartX / xStep);
+        const coreOutStartY = Math.floor(coreGridStartY / yStep);
+        const coreOutEndX = Math.floor(coreGridEndX / xStep);
+        const coreOutEndY = Math.floor(coreGridEndY / yStep);
+        const coreOutWidth = coreOutEndX - coreOutStartX + 1;
+        const coreOutHeight = coreOutEndY - coreOutStartY + 1;
+
+        // Tile's extended region start in grid coordinates
+        const extOutStartX = Math.floor(extGridStartX / xStep);
+        const extOutStartY = Math.floor(extGridStartY / yStep);
+
+        // Copy entire rows at once (works for all stepping values)
+        for (let outY = 0; outY < coreOutHeight; outY++) {
+            const globalOutY = coreOutStartY + outY;
+            const tileOutY = globalOutY - extOutStartY;
+
+            if (globalOutY >= 0 && globalOutY < globalNumScanlines &&
+                tileOutY >= 0 && tileOutY < tileResult.numScanlines) {
+
+                const globalRowStart = globalOutY * globalPointsPerLine + coreOutStartX;
+                const tileRowStart = tileOutY * tileResult.pointsPerLine + (coreOutStartX - extOutStartX);
+
+                // Bulk copy entire row of output values
+                result.set(tileData.subarray(tileRowStart, tileRowStart + coreOutWidth), globalRowStart);
+                copiedCount += coreOutWidth;
+            }
+        }
+
+        debug.log(`  Tile ${tile.id}: copied ${copiedCount} values`);
+    }
+
+    // Count how many output values are still NaN (gaps)
+    let nanCount = 0;
+    for (let i = 0; i < result.length; i++) {
+        if (isNaN(result[i])) nanCount++;
+    }
+    debug.log(`Stitching complete: ${result.length} total values, ${nanCount} still NaN`);
+
+    return {
+        pathData: result,
+        numScanlines: globalNumScanlines,
+        pointsPerLine: globalPointsPerLine,
+        generationTime: 0 // Sum from tiles if needed
+    };
+}