@protoboardai/ext-enclosure-cad 0.0.0-stage → 0.2.0

package/py/enclosure_cad.py

@@ -0,0 +1,1731 @@
+"""enclosure-cad: an enclosure generated from what it holds (build123d).
+
+    python enclosure_cad.py build <job.json> <out_dir> [--root <project root>]
+    python enclosure_cad.py fit <fit.json | ->
+
+The job (lib/job.ts) is everything the generator needs and nothing about
+UHD: the bodies that go inside, placed in the enclosure's coordinates (mm,
+Z up) as GLB files with a 4x4 matrix each; the features the enclosure must
+provide (openings, button plungers, windows, light pipes, insert bosses,
+seal glands, threads, strap lugs, the lid joint), each with its frame or
+the frame of the part it serves; and the design values from the module's
+cad.config.ts (process, material, wall, clearances, split plane, fasteners).
+
+The cavity is the bounding box (or cylinder) of the contents plus the
+clearance, unless the config fixes it. The shell is cut at the split plane
+into a base and a lid; button plungers are separate printed parts, made
+last so their flanges can be trimmed to clear the walls and what is inside.
+Every feature is applied to every part its tool reaches; a cut through a
+side wall is checked part by part across the wall (wall_bands), and a sliver
+it would leave at the joint inside the wall is cut away with it.
+
+`build` writes into <out_dir>:
+  parts/<part>.step|.glb|.stl|.3mf   one printed part each
+  body.step, body.glb                every part, plus one named sub-shape
+                                     per feature (named by its interface id)
+  body.manifest.json                 UHD geometry manifest: feature
+                                     signatures, volumes, frames
+  section.svg                        a section through the cavity centre
+  report.json                        cavity, parts, feature frames and facts
+                                     (recess, gap, squeeze, ledges, walls),
+                                     problems, and the fit analysis (bodies
+                                     inside, and the plungers)
+and prints the report summary as one JSON line. (The provider moves
+report.json next to the job, out of the build cache.)
+
+`fit` runs only the fit analysis (fit.py) on parts already built and the
+bodies a check names, and prints the result: the check uses it when what
+goes inside has changed since the enclosure was generated.
+
+Outputs are deterministic for a fixed job and build123d version.
+"""
+from __future__ import annotations
+
+import hashlib
+import json
+import math
+import re
+import sys
+from pathlib import Path
+
+import build123d as bd
+import numpy as np
+from build123d import (
+    ExportDXF,
+    Unit,
+    Align,
+    Axis,
+    Box,
+    BuildLine,
+    BuildPart,
+    BuildSketch,
+    Circle,
+    Compound,
+    Cylinder,
+    Face,
+    Helix,
+    Location,
+    Mesher,
+    Plane,
+    Polyline,
+    Pos,
+    Rot,
+    Rectangle,
+    RectangleRounded,
+    Shape,
+    Solid,
+    Vector,
+    export_gltf,
+    export_step,
+    export_stl,
+    make_face,
+    offset,
+    revolve,
+    sweep,
+)
+
+HERE = Path(__file__).resolve().parent
+sys.path.insert(0, str(HERE))
+from fit import analyse, analyse_plungers, load_mesh, sample_surface  # noqa: E402
+
+GENERATOR = Path(__file__)
+FIXED_TIME = "2000-01-01T00:00:00"
+TOOL = "build123d"
+MIN = (Align.CENTER, Align.CENTER, Align.MIN)
+
+
+# ---------------------------------------------------------------------------------------------
+# Small geometry helpers
+# ---------------------------------------------------------------------------------------------
+
+
+def unit(v) -> np.ndarray:
+    v = np.asarray(v, dtype=float)
+    n = np.linalg.norm(v)
+    return v / n if n > 1e-12 else v
+
+
+def basis(normal, x_axis=None) -> tuple[np.ndarray, np.ndarray, np.ndarray]:
+    """Orthonormal x, y, z (= normal). Without an xAxis, x is horizontal (or +X for a vertical normal)."""
+    z = unit(normal)
+    if x_axis is not None:
+        x = np.asarray(x_axis, dtype=float)
+    elif abs(z[2]) > 0.9:
+        x = np.array([1.0, 0.0, 0.0])
+    else:
+        x = np.cross([0.0, 0.0, 1.0], z)
+    x = unit(x - z * np.dot(x, z))
+    return x, np.cross(z, x), z
+
+
+def plane_at(origin, normal, x_axis=None) -> Plane:
+    x, _, z = basis(normal, x_axis)
+    return Plane(origin=Vector(*map(float, origin)), x_dir=Vector(*x), z_dir=Vector(*z))
+
+
+def r3(v) -> list[float]:
+    return [round(float(x), 3) + 0.0 for x in v]
+
+
+def frame_of(origin, normal, x_axis=None) -> dict:
+    x, _, z = basis(normal, x_axis)
+    return {"origin": r3(origin), "normal": r3(z), "xAxis": r3(x)}
+
+
+def prism(pl: Plane, sketch_face: Face, z0: float, z1: float) -> Solid:
+    """Extrude a face drawn in the plane's local XY from local z0 to z1."""
+    f = sketch_face.moved(Location((0, 0, z0)))
+    s = Solid.extrude(f, Vector(0, 0, z1 - z0))
+    return pl.location * s
+
+
+def extrude_region(region, z0: float, dz: float) -> Shape:
+    """Extrude a planar region (a face, or several) drawn at z = 0 from z0 by dz."""
+    solids = [Solid.extrude(f.moved(Location((0, 0, z0))), Vector(0, 0, dz)) for f in region.faces()]
+    out = solids[0]
+    for s in solids[1:]:
+        out = out + s
+    return out
+
+
+def section_face(shape: str, width: float, height: float, radius: float = 0.0) -> Face:
+    if shape == "round":
+        return Circle(width / 2).face()
+    if radius > 1e-6 and radius * 2 < min(width, height):
+        return RectangleRounded(width, height, radius).face()
+    return Rectangle(width, height).face()
+
+
+def signature(faces: list[Face]) -> dict:
+    """Area, area-weighted centroid and, when every face is planar and parallel, the shared normal."""
+    area = sum(f.area for f in faces)
+    c = [sum(getattr(f.center(bd.CenterOf.MASS), k) * f.area for f in faces) / area for k in "XYZ"]
+    sig = {"area_mm2": round(area, 3), "centroid": [round(v, 3) + 0.0 for v in c], "faces": len(faces)}
+    normals = set()
+    for f in faces:
+        if f.geom_type != bd.GeomType.PLANE:
+            return sig
+        n = f.normal_at()
+        normals.add((round(n.X, 3) + 0.0, round(n.Y, 3) + 0.0, round(n.Z, 3) + 0.0))
+    if len(normals) == 1:
+        sig["normal"] = list(normals.pop())
+    return sig
+
+
+def faces_on(part: Shape, tool: Shape, tol: float = 1e-3) -> list[Face]:
+    """Faces of `part` lying on the skin of `tool` (the faces a cut or an added solid made)."""
+    skin = Compound(tool.faces())
+    bb = tool.bounding_box()
+    out = []
+    for f in part.faces():
+        fb = f.bounding_box()
+        if fb.min.X > bb.max.X + tol or fb.max.X < bb.min.X - tol or fb.min.Y > bb.max.Y + tol or fb.max.Y < bb.min.Y - tol or fb.min.Z > bb.max.Z + tol or fb.max.Z < bb.min.Z - tol:
+            continue
+        vs, _ = f.tessellate(0.2)
+        pts = vs[:: max(1, len(vs) // 10)]
+        if all(skin.distance_to(p) < tol for p in pts):
+            out.append(f)
+    return out
+
+
+def feature_shape(name: str, faces: list[Face], pad: float = 0.2) -> Compound | None:
+    """A thin named solid over a feature's faces: its sub-shape in body.step and node in body.glb."""
+    solids = []
+    for f in faces:
+        try:
+            solids.append(Solid.extrude(f, f.normal_at() * pad) if f.geom_type == bd.GeomType.PLANE else Solid.thicken(f, pad))
+        except Exception:  # noqa: BLE001 - a face the kernel cannot thicken is left out of the marker
+            continue
+    return Compound(label=name, children=solids) if solids else None
+
+
+# ---------------------------------------------------------------------------------------------
+# The enclosure
+# ---------------------------------------------------------------------------------------------
+
+
+class Enclosure:
+    """Cavity, outline and z levels, from the contents and the design values."""
+
+    def __init__(self, job: dict, bodies: list[dict]):
+        self.job = job
+        self.d = d = job["design"]
+        self.problems: list[str] = []
+        self.shape = d["shape"]
+        self.wall = d["wall"]
+        self.floor = d["floor"]
+        self.lid = d["lid"]
+        self.clr = d["clearance"]
+        self.mw = d["min_wall"]
+        feats = job["features"]
+        self.joint_feature = next((f for f in feats if f["kind"] == "joint"), None)
+        self.joint_gland = next((f for f in feats if f["kind"] == "seal_gland" and f["params"].get("at") == "joint" and f["params"]["type"] == "face"), None)
+        self.collar_gland = next((f for f in feats if f["kind"] == "seal_gland" and f["params"].get("at") == "joint" and f["params"]["type"] == "radial"), None)
+        self.twist = next((f for f in feats if f["kind"] == "twist_lid"), None)
+        jd = d["joint"]
+        self.joint_style = "twist" if self.twist else "flat" if self.joint_gland else jd["style"]
+        if self.twist and self.joint_gland:
+            self.problems.append(f"{self.joint_gland['id']}: a twist lid seals on its collar: make the joint gland radial (SealGland type radial, at joint)")
+        if self.collar_gland and not self.twist:
+            self.problems.append(f"{self.collar_gland['id']}: a radial gland at the joint seals a twist lid's collar; the module has no TwistLid")
+        self.lip = jd["lip_height"]
+        self.jc = jd["clearance"]
+        # rabbet: the base's tongue inside, the lid's skirt outside it, the joint clearance between; tongue and skirt get the same width
+        self.w_out = (self.wall + self.jc) / 2
+
+        verts = [b["V"] for b in bodies if len(b["V"])]
+        if not verts and not d.get("cavity"):
+            raise SystemExit("nothing to enclose: no body inside has geometry, and the config fixes no cavity")
+        allv = np.concatenate(verts) if verts else np.zeros((0, 3))
+        self.contents_lo = allv.min(axis=0) if len(allv) else None
+        self.contents_hi = allv.max(axis=0) if len(allv) else None
+
+        fixed = d.get("cavity")
+        if self.shape == "round":
+            if fixed:
+                self.centre = np.array(fixed["centre"], dtype=float)
+                self.r_cav = float(fixed["radius"])
+                z0, z1 = fixed["z"]
+            else:
+                self.centre = (self.contents_lo[:2] + self.contents_hi[:2]) / 2
+                self.r_cav = float(np.max(np.hypot(allv[:, 0] - self.centre[0], allv[:, 1] - self.centre[1]))) + self.clr
+                z0, z1 = self.contents_lo[2] - self.clr, self.contents_hi[2] + d["clearance_top"]
+            self.cav_min = np.array([self.centre[0] - self.r_cav, self.centre[1] - self.r_cav, z0])
+            self.cav_max = np.array([self.centre[0] + self.r_cav, self.centre[1] + self.r_cav, z1])
+        else:
+            if fixed:
+                self.cav_min = np.array(fixed["min"], dtype=float)
+                self.cav_max = np.array(fixed["max"], dtype=float)
+            else:
+                self.cav_min = self.contents_lo - self.clr
+                self.cav_max = self.contents_hi + np.array([self.clr, self.clr, d["clearance_top"]])
+            self.centre = (self.cav_min[:2] + self.cav_max[:2]) / 2
+
+        # the floor must leave room below every insert boss for its insert hole and a skin
+        for f in feats:
+            if f["kind"] == "boss":
+                p = f["params"]
+                top = f["frame"]["origin"][2]
+                need = top - max(0.0, p["insert"]["hole_depth_mm"] + self.mw - self.floor)
+                if need < self.cav_min[2]:
+                    if fixed:
+                        self.problems.append(f"{f['id']}: the fixed cavity floor at z {self.cav_min[2]:.2f} leaves no room under the boss for its insert hole ({p['insert']['hole_depth_mm']} mm)")
+                    else:
+                        self.cav_min[2] = need
+                if top < self.cav_min[2] - 1e-6:
+                    self.problems.append(f"{f['id']}: boss top z {top:.2f} is below the cavity floor z {self.cav_min[2]:.2f}")
+        self.z_floor = float(self.cav_min[2])
+        self.z_bottom = self.z_floor - self.floor
+        self.z_cav_top = float(self.cav_max[2])
+        self.z_top = self.z_cav_top + self.lid
+        split = d.get("split_z")
+        if split is None:
+            split = self.z_cav_top if self.joint_style in ("flat", "twist") else self.z_cav_top - self.lip
+        self.z_split = float(split)
+        if not (self.z_floor < self.z_split <= self.z_cav_top + 1e-6):
+            self.problems.append(f"split plane z {self.z_split:.2f} is outside the cavity ({self.z_floor:.2f} to {self.z_cav_top:.2f})")
+
+        # lid screws: columns at the cavity corners (box) or around it (round)
+        self.scheme = d["fasteners"]
+        self.columns: list[np.ndarray] = []
+        self.rc = 0.0
+        if self.scheme == "screws":
+            jf = self.joint_feature
+            if not jf or "insert" not in jf["params"] or "screw" not in jf["params"]:
+                raise SystemExit('fasteners "screws" needs a joint feature stating its screw and insert (enclosure_feature kind "joint")')
+            ins = jf["params"]["insert"]
+            self.rc = ins["hole_d_mm"] / 2 + max(ins.get("min_wall_mm", 0.0), self.mw)
+            self.columns = self.column_centres(jf["params"].get("count", 4))
+        self.cw = self.mw  # wall around a column where it bulges out of the shell
+        self.tw = self.plan_twist() if self.twist else None
+
+    def plan_twist(self) -> dict | None:
+        """A twist lid's collar: radii and levels (TwistLid). Everything is measured from the outer radius in.
+
+        The lid's skirt keeps the shell's outside diameter; its wall behind the lock is at least the
+        minimum wall. The skirt's bore is the sealing surface of the collar's O-ring (a radial gland,
+        Parker's static table: gland depth from the bore to the groove's bottom) and passes over the
+        collar's lock as it goes on. Bottom to top the collar holds: a ledge, the O-ring groove, a
+        ledge, the lock (the thread's turns, or the bayonet's lugs at the top).
+        """
+        if self.shape != "round":
+            self.problems.append(f"{self.twist['id']}: a twist lid needs a round enclosure (design shape round)")
+            return None
+        p = self.twist["params"]
+        lock = p["lock"]
+        mw = self.mw
+        r_o = self.r_cav + self.wall
+        clr = p.get("clearance_mm", 0.2)
+        ax = p.get("axial_clearance_mm", 0.15)
+        g = self.collar_gland["params"] if self.collar_gland else None
+        row = g["table"] if g else None
+        L = (row["depth_mm"][0] + row["depth_mm"][1]) / 2 if row else 0.0
+        G = (row["width_mm"][0] + row["width_mm"][1]) / 2 if row else 0.0
+        E = ((row.get("clearance_mm") or [0.05, 0.13])[0] + (row.get("clearance_mm") or [0.05, 0.13])[1]) / 4 if row else 0.05  # radial: half the diametral clearance
+        # a printed bore comes out undersize: the drawn bore is this much larger (radial), so the bore as
+        # printed lands on Parker's clearance and the groove's depth is measured from that printed bore
+        a = p.get("bore_allowance_mm", 0.0)
+        t: dict = {"lock": lock, "r_o": r_o, "clr": clr, "ax": ax, "L": L, "G": G, "gap": E, "a": a}
+        if lock == "thread":
+            P = p.get("pitch_mm", 2.0)
+            d = p.get("depth_mm", round(0.45 * P, 3))
+            flank = math.radians(p.get("flank_angle_deg", 30.0))
+            turns = p.get("turns", 2.0)
+            skirt = max(mw, 1.2)
+            r_b = r_o - skirt  # the skirt's bore as drawn: the lid thread's root and the seal's bore
+            t.update({"P": P, "d": d, "flank": flank, "turns": turns, "r_b": r_b, "r_bp": r_b - a, "r_c": r_b - a - E, "r_major": r_b - a - clr, "r_root": r_b - a - clr - d, "r_crest": r_b - d, "skirt": skirt})
+            lock_h = turns * P + P
+            t["base_wall_lock"] = t["r_root"] - self.r_cav
+        else:
+            d = p.get("lug_depth_mm", 1.0)
+            h = p.get("lug_height_mm", 2.0)
+            n = int(p.get("lugs", 3))
+            w = p.get("lug_width_mm", 6.0)
+            kw = p.get("key_lug_width_mm")
+            twist = p.get("twist_deg", 30.0)
+            r_c = r_o - mw - d - clr  # the slot's floor leaves the minimum wall in the skirt
+            # the first lug (on +Y) may be wider, a key: its slot is the only one it enters, so the lid goes on one way
+            widths = [kw if kw else w] + [w] * (n - 1)
+            angles = [90.0 + 360.0 * k / n for k in range(n)]
+            t.update({"d": d, "h_lug": h, "n": n, "w": w, "widths": widths, "angles": angles, "twist": twist, "r_c": r_c, "r_bp": r_c + E, "r_b": r_c + E + a, "skirt": r_o - (r_c + E + a), "skirt_behind_slot": r_o - (r_c + d + clr)})
+            t["positions"] = bayonet_positions(angles, widths, clr, r_c)
+            tid = self.twist["id"]
+            if kw and kw <= w + 2 * clr + 1e-6:
+                self.problems.append(f"{tid}: the key lug ({kw} mm) must be wider than a slot for the others ({w} mm + 2 x {clr} mm clearance), or it enters any slot")
+            if t["positions"] > 1 and p.get("orientation", "keyed") != "any":
+                self.problems.append(f"{tid}: the lid goes on in {t['positions']} positions {360 / t['positions']:g}° apart, so what is in the lid may not stand over what it serves; key it (key_lug_width_mm wider than lug_width_mm + 2 x clearance), or say orientation \"any\"")
+            # neighbouring slots (each entry plus its run along the twist) keep the minimum wall between them
+            r_slot = r_c + d + clr
+            for i in range(n):
+                j = (i + 1) % n
+                c_ang = math.degrees(clr / r_c)
+                end_i = angles[i] + math.degrees(widths[i] / r_c) / 2 + c_ang
+                start_j = angles[j] + (360.0 if j == 0 else 0.0) - twist - math.degrees(widths[j] / r_c) / 2 - c_ang
+                web = math.radians(start_j - end_i) * r_slot
+                if web < mw - 1e-6:
+                    self.problems.append(f"{tid}: the slots for lugs {i + 1} and {j + 1} leave {web:.2f} mm of skirt between them, under the {mw} mm minimum; fewer or narrower lugs, or a smaller twist")
+            lock_h = 2 * ax + mw + d + h
+            t["base_wall_lock"] = r_c - self.r_cav
+        t["r_g"] = t["r_bp"] - L if g else None
+        # levels, bottom to top. Thread: the groove under the thread (the lid's smooth skirt passes over
+        # the thread to it, and its thread never crosses the groove). Bayonet: the lugs low, the groove
+        # above them (the slots run up the skirt's lower part only; the bore above them is whole).
+        seal_h = (mw + G + mw) if g else 0.0
+        t["h"] = round(seal_h + lock_h + (ax if lock == "bayonet" else 0.0), 3)
+        z0 = t["z0"] = self.z_cav_top - t["h"]
+        if lock == "thread":
+            t["zg"] = (z0 + mw, z0 + mw + G) if g else None
+            t["zl"] = (z0 + seal_h, self.z_cav_top)
+        else:
+            zl0 = z0 + 2 * ax + mw  # the skirt's holding face needs a minimum wall under the slot
+            zl1 = zl0 + t["d"] + t["h_lug"]
+            t["zl"] = (zl0, zl1)
+            t["zg"] = (zl1 + ax + mw, zl1 + ax + mw + G) if g else None
+        if t["z0"] < self.z_floor + mw:
+            self.problems.append(f"{self.twist['id']}: the collar ({t['h']:.2f} mm: the O-ring groove and the lock) reaches below the cavity floor; raise the cavity top")
+        if g and t["r_g"] - self.r_cav < mw - 1e-6:
+            self.problems.append(f"{self.collar_gland['id']}: the groove leaves {t['r_g'] - self.r_cav:.2f} mm of wall to the cavity, under the {mw} mm minimum; a thicker wall or a smaller cavity")
+        return t
+
+    def column_centres(self, count: int) -> list[np.ndarray]:
+        rc, clr = self.rc, self.clr
+        if self.shape == "round":
+            reach = self.r_cav + (self.gland_reach() if self.joint_gland else 0.0)
+            r = reach + rc
+            return [self.centre + r * np.array([math.cos(a), math.sin(a)]) for a in [math.pi / 4 + 2 * math.pi * k / count for k in range(count)]]
+        lo = self.contents_lo[:2] if self.contents_lo is not None else self.cav_min[:2]
+        hi = self.contents_hi[:2] if self.contents_hi is not None else self.cav_max[:2]
+        if self.joint_gland:
+            # outside the groove ring: the cavity corner plus the gland's reach and a wall, along the diagonal
+            k = (self.gland_reach() + self.mw + rc) / math.sqrt(2)
+            lo, hi = self.cav_min[:2], self.cav_max[:2]
+        else:
+            k = (rc + clr) / math.sqrt(2)
+        corners = [(lo[0] - k, lo[1] - k), (hi[0] + k, lo[1] - k), (hi[0] + k, hi[1] + k), (lo[0] - k, hi[1] + k)]
+        if count != 4:
+            self.problems.append(f"{count} lid screws: this provider places 4 (one per corner)")
+        return [np.array(c) for c in corners]
+
+    def gland_reach(self) -> float:
+        """Distance from the cavity edge to the outer edge of the joint groove."""
+        g = self.joint_gland["params"]
+        return g["_inner_offset"] + g["_groove_width"]
+
+    # ---- 2D outlines (XY) ----
+    def cavity_face(self, grow: float = 0.0) -> Face:
+        if self.shape == "round":
+            return Pos(*self.centre) * Circle(self.r_cav + grow).face()
+        w, h = (self.cav_max[:2] - self.cav_min[:2]) + 2 * grow
+        r = grow if grow > 0 else 0.0
+        return Pos(*self.centre) * section_face("box", w, h, r)
+
+    def outer_face(self, inset: float = 0.0) -> Face:
+        """The shell outline (cavity + wall, joined with the columns' bosses), inset by `inset`."""
+        base = self.cavity_face(self.wall - inset)
+        cols = [Pos(*c) * Circle(self.rc + self.cw - inset).face() for c in self.columns if self.rc + self.cw - inset > 0]
+        f = base
+        for c in cols:
+            f = f + c
+        return f.faces()[0] if len(f.faces()) == 1 else f
+
+    def cavity_region(self) -> Face:
+        f = self.cavity_face()
+        for c in self.columns:
+            f = f - Pos(*c) * Circle(self.rc).face()
+        return f
+
+    def outer_bounds(self) -> tuple[np.ndarray, np.ndarray]:
+        lo = np.array([*(self.cav_min[:2] - self.wall), self.z_bottom])
+        hi = np.array([*(self.cav_max[:2] + self.wall), self.z_top])
+        return lo, hi
+
+    def wall_bands(self) -> list[dict]:
+        """Bands across a side wall (depth from the outer surface) and the z span each part holds in each.
+
+        A flat joint is one band split at the split plane. A rabbet is three: the
+        lid's skirt on the outside, the joint clearance, and the base's tongue on
+        the inside (the lid sits over the tongue, clear of it by the joint
+        clearance). Bands inside the wall are hidden once the case is closed.
+        """
+        zb, zs, zt = self.z_bottom, self.z_split, self.z_top
+        if self.joint_style != "rabbet":
+            return [{"band": "wall", "depth": (0.0, self.wall), "hidden": False, "parts": {"base": (zb, zs), "lid": (zs, zt)}}]
+        skirt = self.w_out - self.jc
+        over = zs + self.lip + self.jc
+        return [
+            {"band": "lid skirt", "depth": (0.0, skirt), "hidden": False, "parts": {"base": (zb, zs), "lid": (zs, zt)}},
+            {"band": "joint clearance", "depth": (skirt, self.w_out), "hidden": True, "parts": {"base": (zb, zs), "lid": (over, zt)}},
+            {"band": "tongue", "depth": (self.w_out, self.wall), "hidden": True, "parts": {"base": (zb, zs + self.lip), "lid": (over, zt)}},
+        ]
+
+    def wall_hit(self, origin, normal) -> tuple[np.ndarray | None, float, str]:
+        """Where a ray from `origin` along `normal` leaves the shell, the wall thickness there, and which wall."""
+        o = np.asarray(origin, dtype=float)
+        n = unit(normal)
+        if abs(n[2]) > math.cos(math.radians(10)):
+            z = self.z_top if n[2] > 0 else self.z_bottom
+            t = (z - o[2]) / n[2]
+            return o + t * n, (self.lid if n[2] > 0 else self.floor), ("top" if n[2] > 0 else "bottom")
+        if abs(n[2]) > math.sin(math.radians(10)):
+            return None, 0.0, "a wall at an angle (this provider cuts openings square to a wall)"
+        if self.shape == "round":
+            c = np.array([*self.centre, o[2]])
+            r = self.r_cav + self.wall
+            d = o - c
+            b = np.dot(d[:2], n[:2])
+            cc = np.dot(d[:2], d[:2]) - r * r
+            disc = b * b - cc * np.dot(n[:2], n[:2])
+            if disc < 0:
+                return None, 0.0, "outside the case"
+            t = (-b + math.sqrt(disc)) / np.dot(n[:2], n[:2])
+            return o + t * n, self.wall, "side"
+        a = int(np.argmax(np.abs(n[:2])))
+        if abs(n[a]) < math.cos(math.radians(10)):
+            return None, 0.0, "a corner (the normal is not square to a side wall)"
+        lo, hi = self.outer_bounds()
+        plane = hi[a] if n[a] > 0 else lo[a]
+        t = (plane - o[a]) / n[a]
+        return o + t * n, self.wall, ("+x", "+y")[a] if n[a] > 0 else ("-x", "-y")[a]
+
+
+# ---------------------------------------------------------------------------------------------
+# Features
+# ---------------------------------------------------------------------------------------------
+
+
+class Built:
+    def __init__(self):
+        self.cuts: list[tuple[str, Shape]] = []  # (feature id, tool) cut from every part
+        self.adds: list[tuple[str, Shape]] = []  # (feature id, solid) added to the base
+        self.lid_adds: list[tuple[str, Shape]] = []  # (feature id, solid) added to the lid
+        self.base_steps: list[tuple[str, Shape]] = []  # (feature id, tool) cut from the base before anything is added (a twist lid's collar)
+        self.base_cuts: list[tuple[str, Shape]] = []  # (feature id, tool) cut from the base only (a twist lid's O-ring groove)
+        self.lid_cuts: list[tuple[str, Shape]] = []  # (feature id, tool) cut from the lid only (a twist lid's slots)
+        self.covers: dict[str, dict] = {}  # window feature id -> its cover, in the cover's own frame (not part of the case body)
+        self.marks: dict[str, list[tuple[str, Shape]]] = {}  # feature id -> (part, skin tool) for its signature faces
+        self.extra_parts: dict[str, Shape] = {}
+        self.frames: dict[str, dict] = {}
+        self.facts: dict[str, dict] = {}
+        self.walls: list[dict] = []
+        self.problems: list[str] = []
+        self.zones: dict[str, list[dict]] = {}
+        self.plungers: dict[str, dict] = {}  # feature id -> what make_plunger needs
+        self.solids: list[dict] = []  # solids standing in the cavity (bosses, columns, gland bosses), for the exact fit
+
+
+def served_axis(f: dict) -> tuple[np.ndarray, np.ndarray, np.ndarray | None]:
+    s = f.get("served") or {}
+    fr = s.get("frame") or f.get("frame")
+    if not fr:
+        raise ValueError(f"{f['id']}: no frame and nothing it serves")
+    return np.asarray(fr["origin"], dtype=float), unit(fr["normal"]), (np.asarray(fr["xAxis"], dtype=float) if fr.get("xAxis") else None)
+
+
+def wall_feature(e: Enclosure, b: Built, f: dict) -> tuple[Plane, float, float] | None:
+    """Plane on the outer wall where the feature's axis leaves the shell, the wall there, and the recess of what it serves."""
+    o, n, x = served_axis(f)
+    hit, wall, where = e.wall_hit(o, n)
+    if hit is None:
+        b.problems.append(f"{f['id']}: its axis meets {where}")
+        return None
+    pl = plane_at(hit, n, x)
+    xa = np.array([pl.x_dir.X, pl.x_dir.Y, pl.x_dir.Z])
+    b.frames[f["id"]] = frame_of(hit, n, xa)
+    recess = float(np.dot(hit - o, n))
+    return pl, wall, recess
+
+
+def through(e: Enclosure, pl: Plane, half: float) -> float:
+    """How far past the wall (measured on the feature's axis) a cut must reach to clear the cavity
+    everywhere across its half-width: on a round shell's side wall the cavity face curves away from
+    the axis, by r - sqrt(r^2 - half^2) at the cut's edge."""
+    n = np.array([pl.z_dir.X, pl.z_dir.Y, pl.z_dir.Z])
+    if e.shape != "round" or abs(n[2]) > 0.5 or half >= e.r_cav:
+        return 0.2
+    return 0.2 + e.r_cav - math.sqrt(e.r_cav * e.r_cav - half * half)
+
+
+def edge_margins(e: Enclosure, b: Built, f: dict, pl: Plane, width: float, height: float, what: str, depth: tuple[float, float] | None = None, corner: float = 0.0) -> dict:
+    """What each part keeps above and below a cut through a side wall, band by band across the wall (exact).
+
+    `depth` is how far into the wall the cut reaches from the outer surface
+    (default: through it); `corner` the radius of the cut's top and bottom
+    corners. A sliver thinner than the minimum wall that the cut leaves at the
+    joint inside the wall (on the rabbet's tongue, or the lid over it) is cut
+    away with it: the other part closes the gap there, and nothing shows from
+    outside. Anything else thinner than the minimum (on the outer face, at the
+    top or bottom of the case) is reported as a wall.
+    """
+    o = np.array([pl.origin.X, pl.origin.Y, pl.origin.Z])
+    n = np.array([pl.z_dir.X, pl.z_dir.Y, pl.z_dir.Z])
+    if abs(n[2]) > 0.5:
+        return {}
+    x = np.array([pl.x_dir.X, pl.x_dir.Y, pl.x_dir.Z])
+    y = np.array([pl.y_dir.X, pl.y_dir.Y, pl.y_dir.Z])
+    half_z = abs(x[2]) * width / 2 + abs(y[2]) * height / 2
+    h = unit(np.cross([0.0, 0.0, 1.0], n))
+    half_h = abs(np.dot(x, h)) * width / 2 + abs(np.dot(y, h)) * height / 2
+    lo_c, hi_c = o[2] - half_z, o[2] + half_z
+    d0, d1 = depth if depth is not None else (0.0, e.wall)
+    edges = (e.z_top, e.z_bottom)
+    keep: dict[tuple[str, str], tuple[float, str]] = {}
+    cleared = []
+    for band in e.wall_bands():
+        b0, b1 = band["depth"]
+        if d1 <= b0 + 1e-9 or d0 >= b1 - 1e-9:
+            continue  # the cut does not reach this band
+        for part, (plo, phi) in band["parts"].items():
+            if hi_c <= plo + 1e-9 or lo_c >= phi - 1e-9:
+                continue  # the cut misses this part in this band
+            for side, left, edge in (("above", phi - hi_c, phi), ("below", lo_c - plo, plo)):
+                if left <= 1e-6:
+                    continue
+                at_joint = all(abs(edge - z) > 1e-6 for z in edges)
+                if left < e.mw and at_joint and band["hidden"]:
+                    z0, z1 = (hi_c - corner, phi + 0.01) if side == "above" else (plo - 0.01, lo_c + corner)
+                    side_plane = Plane(origin=Vector(*o), x_dir=Vector(*h), z_dir=Vector(*n))
+                    face = Pos(0, (z0 + z1) / 2 - o[2]) * Rectangle(2 * half_h, z1 - z0)
+                    b.cuts.append((f["id"], prism(side_plane, face.face(), -(min(b1, d1) + 0.01), -(max(b0, d0) - 0.01))))
+                    cleared.append({"part": part, "band": band["band"], "side": side, "mm": round(left, 3)})
+                    continue
+                k = (part, side)
+                if k not in keep or left < keep[k][0]:
+                    keep[k] = (left, band["band"])
+    margins: dict[str, dict] = {}
+    for (part, side), (left, band) in sorted(keep.items()):
+        margins.setdefault(part, {})[side] = round(left, 3)
+        b.walls.append({"feature": f["id"], "what": f"{part} {side} the {what} ({band})", "mm": round(left, 3), "min_mm": e.mw})
+    if cleared:
+        margins["cleared"] = cleared
+    return margins
+
+
+def side_half(pl: Plane, width: float, height: float) -> float:
+    """Half the extent of a width x height cut across the horizontal of the wall it passes through (the
+    direction a round cavity's inner face curves away in), for `through`."""
+    n = np.array([pl.z_dir.X, pl.z_dir.Y, pl.z_dir.Z])
+    if abs(n[2]) > 0.5:
+        return max(width, height) / 2
+    x = np.array([pl.x_dir.X, pl.x_dir.Y, pl.x_dir.Z])
+    y = np.array([pl.y_dir.X, pl.y_dir.Y, pl.y_dir.Z])
+    h = unit(np.cross([0.0, 0.0, 1.0], n))
+    return abs(np.dot(x, h)) * width / 2 + abs(np.dot(y, h)) * height / 2
+
+
+def opening(e: Enclosure, b: Built, f: dict) -> None:
+    p = f["params"]
+    w = wall_feature(e, b, f)
+    if not w:
+        return
+    pl, wall, recess = w
+    shape = p.get("shape", "rect")
+    width = p["diameter_mm"] if shape == "round" else p["width_mm"]
+    height = p["diameter_mm"] if shape == "round" else p["height_mm"]
+    corner = width / 2 if shape == "round" else p.get("corner_radius_mm", 0.0)
+    tool = prism(pl, section_face(shape, width, height, p.get("corner_radius_mm", 0.0)), -(wall + through(e, pl, side_half(pl, width, height))), 1.0)
+    b.cuts.append((f["id"], tool))
+    b.marks[f["id"]] = [("*", tool)]
+    b.facts[f["id"]] = {"kind": "opening", "size_mm": [width, height], "recess_mm": round(recess, 3), "wall_mm": wall, "margins_mm": edge_margins(e, b, f, pl, width, height, "opening", corner=corner)}
+    if p.get("plug"):
+        fit = plug_fit(e, pl, width, height, p["plug"])
+        if p.get("seat") == "flat" and fit.get("seat_gap_mm", 0.0) > 0.0:
+            seat_pad(e, b, f, pl, p["plug"], fit)
+        b.facts[f["id"]]["plug"] = fit
+
+
+SEAT_MARGIN_MM = 0.3  # the flat seat stands this far beyond the overmold on each side
+
+
+def seat_pad(e: Enclosure, b: Built, f: dict, pl: Plane, plug: dict, fit: dict) -> None:
+    """A flat seat for a plug's overmold on a round wall: material added outside the wall up to the plane
+    through the opening's outermost point, over the overmold's face plus a margin, within the case's height.
+    The plug then bears on a flat face, and nothing stands proud of that plane (the case's extent along the
+    plug axis is unchanged). The part above the split goes to the lid, the rest to the base."""
+    ow, oh = plug["overmold_width_mm"] + 2 * SEAT_MARGIN_MM, plug["overmold_height_mm"] + 2 * SEAT_MARGIN_MM
+    depth = fit["seat_gap_mm"] + 0.3  # from the plane into the wall, past where the curve leaves it
+    pad = prism(pl, Rectangle(ow, oh).face(), -depth, 0.0)
+    lo, hi = e.outer_bounds()
+    span = float(np.max(hi[:2] - lo[:2])) + 20
+    slab = lambda z0, z1: Pos(*e.centre, z0) * Box(span, span, z1 - z0, align=MIN)  # noqa: E731
+    pad = pad & slab(e.z_bottom, e.z_top)
+    cavity = extrude_region(e.cavity_region(), e.z_floor - 1, e.z_cav_top - e.z_floor + 2)
+    pad = pad - cavity
+    below, above = pad & slab(e.z_bottom - 1, e.z_split), pad & slab(e.z_split, e.z_top + 1)
+    if below is not None and below.volume > 1e-6:
+        b.adds.append((f["id"], below))
+    if above is not None and above.volume > 1e-6:
+        b.lid_adds.append((f["id"], above))
+    fit["seat"] = {"kind": "flat", "width_mm": round(ow, 3), "height_mm": round(oh, 3), "proud_mm": fit["seat_gap_mm"]}
+    fit["seat_gap_mm"] = 0.0
+
+
+def plug_fit(e: Enclosure, pl: Plane, width: float, height: float, plug: dict) -> dict:
+    """Whether the plug a socket opening takes passes through it, and how its overmold seats on the outer face.
+
+    The overmold butts the wall around the opening, so the face must be flat
+    under it: on a box, within the flat side and clear of the screw columns'
+    bulges (seat_mm, the least margin; negative where it overhangs); on a round
+    case, the gap the curve leaves under the overmold's ends (seat_gap_mm).
+    """
+    out = {"name": plug.get("name"), "passes": width >= plug["plug_width_mm"] - 1e-6 and height >= plug["plug_thickness_mm"] - 1e-6, "plug_mm": [plug["plug_width_mm"], plug["plug_thickness_mm"]]}
+    o = np.array([pl.origin.X, pl.origin.Y, pl.origin.Z])
+    n = np.array([pl.z_dir.X, pl.z_dir.Y, pl.z_dir.Z])
+    if abs(n[2]) > 0.5:
+        return out
+    x = np.array([pl.x_dir.X, pl.x_dir.Y, pl.x_dir.Z])
+    ow, oh = plug["overmold_width_mm"], plug["overmold_height_mm"]
+    # the overmold's width lies along the opening's width
+    half_h = (abs(x[2]) * oh + (1 - abs(x[2])) * ow) / 2
+    half_z = (abs(x[2]) * ow + (1 - abs(x[2])) * oh) / 2
+    margins = []
+    # past the case's front or back face the overmold overhangs an edge into air: reported, not a seat fault
+    out["edge_overhang_mm"] = round(max(0.0, -min(o[2] - half_z - e.z_bottom, e.z_top - (o[2] + half_z))), 3)
+    if e.shape == "round":
+        r = e.r_cav + e.wall
+        out["seat_gap_mm"] = round(r - math.sqrt(max(r * r - half_h * half_h, 0.0)), 3)
+    else:
+        a = int(np.argmax(np.abs(n[:2])))
+        lat = 1 - a
+        c = o[lat]
+        margins += [c - half_h - e.cav_min[lat], e.cav_max[lat] - (c + half_h)]
+        rr = e.rc + e.cw
+        for col in e.columns:
+            d = (col[a] - o[a]) * math.copysign(1.0, n[a])  # how far the column's centre stands out of the face
+            if d <= -rr:
+                continue
+            # the lateral span over which its bulge stands out of the face
+            span = rr if d >= 0 else math.sqrt(rr * rr - d * d)
+            margins.append(max(col[lat] - span - (c + half_h), (c - half_h) - (col[lat] + span)))
+    out["overmold_mm"] = [ow, oh]
+    if margins:
+        out["seat_mm"] = round(min(margins), 3)
+    return out
+
+
+def light_pipe(e: Enclosure, b: Built, f: dict) -> None:
+    p = f["params"]
+    w = wall_feature(e, b, f)
+    if not w:
+        return
+    pl, wall, recess = w
+    d = p["diameter_mm"] + 2 * p.get("clearance_mm", 0.1)
+    tool = prism(pl, Circle(d / 2).face(), -(wall + through(e, pl, d / 2)), 1.0)
+    b.cuts.append((f["id"], tool))
+    b.marks[f["id"]] = [("*", tool)]
+    b.facts[f["id"]] = {"kind": "light_pipe", "hole_d_mm": round(d, 3), "recess_mm": round(recess, 3), "wall_mm": wall, "margins_mm": edge_margins(e, b, f, pl, d, d, "light pipe hole", corner=d / 2)}
+
+
+def window(e: Enclosure, b: Built, f: dict) -> None:
+    p = f["params"]
+    w = wall_feature(e, b, f)
+    if not w:
+        return
+    pl, wall, recess = w
+    ap, cv = p["aperture"], p["cover"]
+    shape = "round" if "diameter_mm" in ap else "rect"
+    aw, ah = (ap["diameter_mm"],) * 2 if shape == "round" else (ap["width_mm"], ap["height_mm"])
+    c = p.get("clearance_mm", 0.1)
+    cw, ch = (cv["diameter_mm"] + 2 * c,) * 2 if shape == "round" else (cv["width_mm"] + 2 * c, cv["height_mm"] + 2 * c)
+    t = cv["thickness_mm"]
+    r = p.get("corner_radius_mm", 0.0)
+    aperture = prism(pl, section_face(shape, aw, ah, r), -(wall + through(e, pl, max(aw, ah) / 2)), 1.0)
+    side = p.get("side", "outside")
+    z0, z1 = (-t, 1.0) if side == "outside" else (-(wall + through(e, pl, max(cw, ch) / 2)), -(wall - t))
+    pocket = prism(pl, section_face(shape, cw, ch, r + c if r else 0.0), z0, z1)
+    b.cuts += [(f["id"], aperture), (f["id"], pocket)]
+    b.marks[f["id"]] = [("*", pocket)]
+    ledge = min(cw - aw, ch - ah) / 2
+    corner_a, corner_c = (aw / 2, cw / 2) if shape == "round" else (r, r + c if r else 0.0)
+    edge_margins(e, b, f, pl, aw, ah, "aperture", corner=corner_a)
+    edge_margins(e, b, f, pl, cw, ch, "cover pocket", depth=(0.0, t) if side == "outside" else (wall - t, wall), corner=corner_c)
+    b.facts[f["id"]] = {"kind": "window", "aperture_mm": [aw, ah], "pocket_mm": [round(cw, 3), round(ch, 3)], "pocket_depth_mm": t, "side": side, "ledge_mm": round(ledge, 3), "recess_mm": round(recess, 3), "wall_mm": wall}
+    # the cover itself, in its own frame: its outer face at z 0, its body behind it along +z (into the case), x
+    # along the window's x. The frame mates flush with the window's frame (the outer surface). An inside cover is
+    # not drawn: what holds it is the project's. Nor is a cover whose material is "none…": the pocket is only a
+    # counterbore (a plug's overmold seats in it) and nothing is fitted.
+    if side == "outside" and not str(cv.get("material") or "").lower().startswith("none"):
+        cr = r if shape != "round" else 0.0
+        outline = section_face(shape, cv["diameter_mm"] if shape == "round" else cv["width_mm"], cv["diameter_mm"] if shape == "round" else cv["height_mm"], cr)
+        b.covers[f["id"]] = {"solid": Solid.extrude(outline, Vector(0, 0, t)), "placed": prism(pl, outline, -t, 0.0), "outline": outline, "material": cv.get("material"), "thickness_mm": t, "size_mm": [cv["diameter_mm"]] if shape == "round" else [cv["width_mm"], cv["height_mm"]], "shape": shape}
+    b.walls.append({"feature": f["id"], "what": "ledge holding the cover", "mm": round(ledge, 3), "min_mm": e.mw})
+    b.walls.append({"feature": f["id"], "what": "wall left under the cover pocket", "mm": round(wall - t, 3), "min_mm": e.mw})
+
+
+def button(e: Enclosure, b: Built, f: dict) -> None:
+    p = f["params"]
+    w = wall_feature(e, b, f)
+    if not w:
+        return
+    pl, wall, recess = w
+    hole = p["hole_d_mm"]
+    shaft = hole - 2 * p.get("clearance_mm", 0.15)
+    gap = p.get("gap_mm", 0.1)
+    out = p.get("protrude_mm", 1.0)
+    fd, ft = p.get("flange_d_mm", hole + 2.0), p.get("flange_mm", 0.8)
+    bore = prism(pl, Circle(hole / 2).face(), -(wall + through(e, pl, hole / 2)), 1.0)
+    margins = edge_margins(e, b, f, pl, hole, hole, "plunger bore", corner=hole / 2)
+    b.cuts.append((f["id"], bore))
+    b.marks[f["id"]] = [("*", bore)]
+    tip = -(recess - gap)
+    room = recess - gap - wall - ft
+    if room < 0.1:
+        b.problems.append(f"{f['id']}: {recess:.2f} mm from the outer wall to the actuator leaves no room for a {ft} mm plunger flange behind a {wall} mm wall")
+    # the plunger is made once the walls are built: its flange is trimmed to clear them and what is inside
+    b.plungers[f["id"]] = {"plane": pl, "shaft": shaft, "hole": hole, "tip": tip, "out": out, "flange_d": fd, "flange": (-(wall + 0.1 + ft), -(wall + 0.1)), "gap": gap}
+    n = np.array([pl.z_dir.X, pl.z_dir.Y, pl.z_dir.Z])
+    tip_pt = np.array([pl.origin.X, pl.origin.Y, pl.origin.Z]) + n * tip
+    b.facts[f["id"]] = {
+        "kind": "button",
+        "hole_d_mm": hole,
+        "shaft_d_mm": round(shaft, 3),
+        "plunger": f"plunger_{f['id']}",
+        "tip": r3(tip_pt),
+        "gap_mm": gap,
+        "travel_mm": p.get("travel_mm"),
+        "length_mm": round(out - tip, 3),
+        "recess_mm": round(recess, 3),
+        "wall_mm": wall,
+        "margins_mm": margins,
+    }
+
+
+# the plunger flange must overlap the wall around the bore by this much over at least half its edge, or the
+# plunger can tilt out through the bore (assumption: about one 0.4 mm extrusion plus the shaft clearance)
+FLANGE_HOLD_MM = 0.5
+FLANGE_HOLD_FRACTION = 0.5
+
+
+def clip_polygon(poly: np.ndarray, axis: int, bound: float, keep_below: bool) -> np.ndarray:
+    """Sutherland-Hodgman: the part of a convex polygon on one side of an axis-aligned plane."""
+    if not len(poly):
+        return poly
+    out = []
+    for i in range(len(poly)):
+        a, c = poly[i], poly[(i + 1) % len(poly)]
+        ina = a[axis] <= bound if keep_below else a[axis] >= bound
+        inc = c[axis] <= bound if keep_below else c[axis] >= bound
+        if ina:
+            out.append(a)
+        if ina != inc:
+            t = (bound - a[axis]) / (c[axis] - a[axis])
+            out.append(a + t * (c - a))
+    return np.array(out)
+
+
+def points_near(V: np.ndarray, F: np.ndarray, pl: Plane, reach: float, z0: float, z1: float, step: float) -> np.ndarray:
+    """Surface points of a mesh within `reach` of the plane's axis and between local z0 and z1, in the plane's local coordinates."""
+    if not len(F):
+        return np.zeros((0, 3))
+    o = np.array([pl.origin.X, pl.origin.Y, pl.origin.Z])
+    R = np.array([[pl.x_dir.X, pl.x_dir.Y, pl.x_dir.Z], [pl.y_dir.X, pl.y_dir.Y, pl.y_dir.Z], [pl.z_dir.X, pl.z_dir.Y, pl.z_dir.Z]])
+    tri = ((V - o) @ R.T)[F]
+    lo, hi = tri.min(axis=1), tri.max(axis=1)
+    sel = (lo[:, 0] <= reach) & (hi[:, 0] >= -reach) & (lo[:, 1] <= reach) & (hi[:, 1] >= -reach) & (lo[:, 2] <= z1) & (hi[:, 2] >= z0)
+    out = []
+    for t in tri[sel]:
+        poly = t
+        for axis, bound, below in ((0, reach, True), (0, -reach, False), (1, reach, True), (1, -reach, False), (2, z1, True), (2, z0, False)):
+            poly = clip_polygon(poly, axis, bound, below)
+        if len(poly) == 0:
+            continue
+        if len(poly) < 3:
+            out.append(poly)
+            continue
+        fan = np.array([[0, i, i + 1] for i in range(1, len(poly) - 1)])
+        out.append(sample_surface(poly, fan, step))
+    return np.concatenate(out) if out else np.zeros((0, 3))
+
+
+def flange_outline(obstacles: list[tuple[str, np.ndarray, float]], slab: tuple[float, float], clearance: float, r_max: float, count: int = 120) -> tuple[np.ndarray, np.ndarray, list[str]]:
+    """Largest radius the flange may have at each angle and stay `clearance` clear of every obstacle point.
+
+    obstacles: (name, local points, normal margin): a point counts when it lies
+    within the margin of the flange's slab along the axis; its in-plane
+    allowance shrinks with that distance (a sphere of the clearance). Returns
+    the angles, the radius at each (taking the least of each angle and its two
+    neighbours, so the polygon's edges stay clear too) and what limited it.
+    """
+    ang = np.arange(count) * 2 * math.pi / count
+    r = np.full(count, r_max)
+    who = np.full(count, -1)
+    names = []
+    for k, (name, pts, margin) in enumerate(obstacles):
+        names.append(name)
+        if not len(pts):
+            continue
+        dn = np.maximum(slab[0] - pts[:, 2], pts[:, 2] - slab[1])
+        dn = np.maximum(dn, 0.0)
+        ok = dn <= margin + 1e-9
+        pts, dn = pts[ok], dn[ok]
+        if not len(pts):
+            continue
+        ci = np.sqrt(np.maximum(clearance**2 - dn**2, 0.0)) if margin > 0 else np.full(len(pts), clearance)
+        # where the ray at each angle first comes within the allowance of each point: projected along it, less the half-chord
+        u = np.stack([np.cos(ang), np.sin(ang)], axis=1)
+        rh = np.full(count, np.inf)
+        for i in range(0, len(pts), 20000):
+            q, cq = pts[i : i + 20000, :2], ci[i : i + 20000]
+            along = u @ q.T
+            perp2 = np.maximum((q * q).sum(axis=1)[None, :] - along**2, 0.0)
+            hit = (along > 0) & (perp2 < cq[None, :] ** 2)
+            rh = np.minimum(rh, np.where(hit, along - np.sqrt(np.maximum(cq[None, :] ** 2 - perp2, 0.0)), np.inf).min(axis=1))
+        better = rh < r
+        r = np.where(better, rh, r)
+        who = np.where(better, k, who)
+    r = np.minimum.reduce([r, np.roll(r, 1), np.roll(r, -1)])
+    limited = sorted({names[k] for k in who if k >= 0})
+    return ang, r, limited
+
+
+def make_plunger(e: Enclosure, b: Built, fid: str, spec: dict, walls: dict[str, tuple[np.ndarray, np.ndarray]], bodies: list[dict]) -> Shape:
+    """A plunger: the shaft from the tip to outside the wall, and a flange behind the wall trimmed to clear the walls and what is inside."""
+    pl = spec["plane"]
+    z0, z1 = spec["flange"]
+    shaft_r = spec["shaft"] / 2
+    r_max = spec["flange_d"] / 2
+    step = 0.1
+    # obstacle surfaces are sampled `step` apart, so the flange keeps half a step more than the clearance from each sample
+    c = e.clr + step / 2
+    reach = r_max + c + 0.1
+    # walls count only across the flange's own thickness (the wall it sits behind is parallel to it); bodies inside within the clearance of it
+    obstacles = [(k, points_near(v, f, pl, reach, z0, z1, step), 0.0) for k, (v, f) in sorted(walls.items())]
+    obstacles += [(body["key"], points_near(body["V"], body["F"], pl, reach, z0 - c, z1 + c, step), c) for body in bodies]
+    ang, r, limited = flange_outline(obstacles, (z0, z1), c, r_max)
+    hole_r = spec["hole"] / 2
+    held = float(np.mean(r - hole_r >= FLANGE_HOLD_MM - 1e-9))
+    if limited:
+        rr = np.maximum(r, shaft_r)
+        pts = [Vector(float(R * math.cos(a)), float(R * math.sin(a)), 0.0) for a, R in zip(ang, rr)]
+        face = Face(bd.Wire.make_polygon(pts, close=True))
+        # the polygon's chords cut a hair inside the shaft's circle where the flange is trimmed to it
+        joined = (face + Circle(shaft_r).face()).faces()
+        face = joined[0] if len(joined) == 1 else face
+    else:
+        face = Circle(r_max).face()
+    shaft_solid = prism(pl, Circle(shaft_r).face(), spec["tip"], spec["out"])
+    flange = prism(pl, face, z0, z1)
+    plunger = shaft_solid + flange
+    b.facts[fid].update(
+        {
+            "flange_d_mm": round(2 * r_max, 3),
+            "flange_trimmed_by": limited,
+            "flange_overlap_mm": [round(float(np.min(r - hole_r)), 3), round(float(np.max(r - hole_r)), 3)],
+            "flange_hold_pct": round(100 * held, 1),
+            "flange_hold_rule": {"overlap_mm": FLANGE_HOLD_MM, "pct": 100 * FLANGE_HOLD_FRACTION},
+        }
+    )
+    return plunger
+
+
+def boss(e: Enclosure, b: Built, f: dict) -> None:
+    p = f["params"]
+    ins = p["insert"]
+    fr = f["frame"]
+    top = fr["origin"][2]
+    if abs(unit(fr["normal"])[2] - 1) > 1e-6:
+        b.problems.append(f"{f['id']}: a boss frame must face +Z (bosses stand on the floor)")
+        return
+    od = ins["hole_d_mm"] + 2 * max(ins.get("min_wall_mm", 0.0), e.mw)
+    od = max(od, p.get("boss_d_mm", 0.0))
+    solids, holes = [], []
+    for hx, hy in p["holes"]:
+        solids.append(Pos(hx, hy, e.z_floor - 0.01) * Cylinder(od / 2, top - e.z_floor + 0.01, align=MIN))
+        holes.append(Pos(hx, hy, top - ins["hole_depth_mm"]) * Cylinder(ins["hole_d_mm"] / 2, ins["hole_depth_mm"] + 0.01, align=MIN))
+    for s in solids:
+        b.adds.append((f["id"], s))
+    for hx, hy in p["holes"]:
+        b.solids.append({"name": f"boss {f['id']}", "part": "base", "origin": [hx, hy, e.z_floor], "axis": [0.0, 0.0, 1.0], "radius": od / 2, "length": top - e.z_floor})
+    for h in holes:
+        b.cuts.append((f["id"], h))
+    tops = [Pos(hx, hy, top - 0.05) * Cylinder(od / 2 + 1e-3, 0.05, align=MIN) for hx, hy in p["holes"]]
+    b.marks[f["id"]] = [("base", t) for t in tops]
+    b.frames[f["id"]] = frame_of(fr["origin"], fr["normal"], fr.get("xAxis"))
+    b.facts[f["id"]] = {"kind": "boss", "boss_d_mm": round(od, 3), "top_z": top, "height_mm": round(top - e.z_floor, 3), "insert": ins, "holes": p["holes"]}
+    b.walls.append({"feature": f["id"], "what": "boss wall around the insert", "mm": round((od - ins["hole_d_mm"]) / 2, 3), "min_mm": max(ins.get("min_wall_mm", 0.0), e.mw)})
+    b.walls.append({"feature": f["id"], "what": "floor skin under the insert hole", "mm": round(top - ins["hole_depth_mm"] - e.z_bottom, 3), "min_mm": e.mw})
+    for key in f.get("mates", []):
+        b.zones.setdefault(key, []).extend({"centre": [hx, hy], "radius": od / 2 + e.clr + 0.5, "z": [top - 1.0, top + 1.0]} for hx, hy in p["holes"])
+
+
+def strap_lugs(e: Enclosure, b: Built, f: dict) -> None:
+    p = f["params"]
+    sgn = 1.0 if p["end"] == "+y" else -1.0
+    s = p["strap_width_mm"]
+    lw = p.get("lug_width_mm", p["hole_depth_mm"] + e.mw + 0.2)
+    bar_r = p["bar_d_mm"] / 2
+    edge = p.get("edge_mm", 1.0)
+    gap = p.get("strap_gap_mm", 2.0)
+    lh = p.get("lug_height_mm", min(4.0, e.z_split - e.z_bottom))
+    z0 = e.z_bottom
+    zc = z0 + lh / 2
+    cx, cy = e.centre
+    xs = [(cx + s / 2, cx + s / 2 + lw), (cx - s / 2 - lw, cx - s / 2)]
+    if e.shape == "round":
+        r_out = e.r_cav + e.wall
+        far = max(abs(xs[0][1] - cx), abs(xs[1][0] - cx))
+        if far >= r_out:
+            b.problems.append(f"{f['id']}: lugs {s} mm apart do not fit on a Ø{2 * r_out:.1f} mm case")
+            return
+        # lugs grow out of the case where they stand; the strap between them clears the case at its centre line
+        y_start = math.sqrt(r_out**2 - far**2) - 0.5
+        reach = r_out
+    else:
+        lo, hi = e.outer_bounds()
+        reach = (hi[1] - cy) if sgn > 0 else (cy - lo[1])
+        y_start = reach - 0.5
+    y_bar = reach + gap + bar_r
+    y_end = y_bar + bar_r + edge
+    for x0, x1 in xs:
+        b.adds.append((f["id"], Pos((x0 + x1) / 2, cy + sgn * (y_start + y_end) / 2, z0) * Box(x1 - x0, y_end - y_start, lh, align=MIN)))
+    hd, hdep = p["hole_d_mm"], p["hole_depth_mm"]
+    holes = []
+    for x_face, dirn in ((xs[0][0], 1.0), (xs[1][1], -1.0)):
+        pl = Plane(origin=Vector(x_face, cy + sgn * y_bar, zc), x_dir=Vector(0, 1, 0), z_dir=Vector(dirn, 0, 0))
+        holes.append(prism(pl, Circle(hd / 2).face(), -0.01, hdep))
+    for h in holes:
+        b.cuts.append((f["id"], h))
+    b.marks[f["id"]] = [("base", h) for h in holes]
+    b.frames[f["id"]] = frame_of([cx, cy + sgn * y_bar, zc], [0, sgn, 0], [1, 0, 0])
+    b.facts[f["id"]] = {"kind": "strap_lugs", "lug_gap_mm": s, "bar_axis": r3([cx, cy + sgn * y_bar, zc]), "hole_d_mm": hd, "hole_depth_mm": hdep, "bar_to_case_mm": round(gap, 3)}
+    b.walls.append({"feature": f["id"], "what": "lug wall beyond the spring-bar hole", "mm": round(lw - hdep, 3), "min_mm": e.mw})
+    b.walls.append({"feature": f["id"], "what": "lug edge beyond the spring-bar hole", "mm": round(y_end - y_bar - hd / 2, 3), "min_mm": e.mw})
+
+
+def thread(e: Enclosure, b: Built, f: dict) -> None:
+    """Internal thread in a skirt under the floor (a cap screwing onto a neck)."""
+    p = f["params"]
+    if e.shape != "round":
+        b.problems.append(f"{f['id']}: threads need a round enclosure (design shape round)")
+        return
+    T, E, P = p["major_d_mm"], p["root_d_mm"], p["pitch_mm"]
+    L = p["length_mm"]
+    clr = p.get("clearance_mm", 0.3)
+    r_root = T / 2 + clr
+    r_crest = E / 2 + clr
+    h = r_root - r_crest
+    skirt = p.get("skirt_wall_mm", e.wall)
+    cx, cy = e.centre
+    z_open = e.z_bottom - L
+    ring = Pos(cx, cy, z_open) * (Cylinder(r_root + skirt, L + 0.01, align=MIN) - Cylinder(r_root, L + 0.01, align=MIN))
+    b.adds.append((f["id"], ring))
+    crest_w = p.get("crest_width_mm", 0.25 * P)
+    flank = math.radians(p.get("flank_angle_deg", 30.0))
+    base_w = crest_w + 2 * h * math.tan(flank)
+    if base_w >= P:
+        b.problems.append(f"{f['id']}: a {h:.2f} mm deep thread with {crest_w} mm crests and {math.degrees(flank):.0f}° flanks is wider ({base_w:.2f} mm) than its {P} mm pitch")
+        return
+    start, end = 0.6 + base_w / 2, L - 0.6 - base_w / 2
+    if end - start < P:
+        b.problems.append(f"{f['id']}: {L} mm of skirt holds less than one turn of a {P} mm pitch thread")
+        return
+    helix = Helix(pitch=P, height=end - start, radius=r_root)
+    with BuildSketch(Plane.XZ) as sk:
+        with BuildLine():
+            Polyline([(r_root + 0.2, -base_w / 2), (r_crest, -crest_w / 2), (r_crest, crest_w / 2), (r_root + 0.2, base_w / 2)], close=True)
+        make_face()
+    ridge = sweep(sk.sketch.faces()[0], path=helix, is_frenet=True)
+    ridge = Pos(cx, cy, z_open + start) * ridge
+    b.adds.append((f["id"], ridge))
+    b.marks[f["id"]] = [("base", ridge)]
+    b.frames[f["id"]] = frame_of([cx, cy, z_open], [0, 0, -1], [1, 0, 0])
+    b.facts[f["id"]] = {"kind": "thread", "major_d_mm": round(2 * r_root, 3), "minor_d_mm": round(2 * r_crest, 3), "pitch_mm": P, "turns": round((end - start) / P, 2), "skirt_length_mm": L, "depth_mm": round(h, 3)}
+    b.walls.append({"feature": f["id"], "what": "skirt wall behind the thread root", "mm": skirt, "min_mm": e.mw})
+
+
+def seal_gland(e: Enclosure, b: Built, f: dict) -> None:
+    p = f["params"]
+    o = p["oring"]
+    row = p["table"]
+    L = (row["depth_mm"][0] + row["depth_mm"][1]) / 2
+    G = (row["width_mm"][0] + row["width_mm"][1]) / 2
+    W = o["w_mm"]
+    fact = {"kind": "seal_gland", "type": p["type"], "oring": o["size"], "w_mm": W, "groove_depth_mm": round(L, 3), "groove_width_mm": round(G, 3), "table": row["source"]}
+    if p["type"] == "radial" and p.get("at") == "joint":
+        t = e.tw
+        if not t:
+            b.problems.append(f"{f['id']}: a radial gland at the joint seals a twist lid's collar; the module has none")
+            return
+        z0, z1 = t["zg"]
+        groove = annulus(t["r_g"], t["r_c"] + 0.01, z0, z1, e.centre)
+        b.base_cuts.append((f["id"], groove))
+        b.marks[f["id"]] = [("base", groove)]
+        b.frames[f["id"]] = frame_of([*e.centre, (z0 + z1) / 2], [0, 0, 1], [1, 0, 0])
+        o = p["oring"]
+        seat = 2 * t["r_g"]
+        fact.update({"at": "joint", "seat_d_mm": round(seat, 3), "bore_d_mm": round(2 * t["r_b"], 3), "printed_bore_d_mm": round(2 * t["r_bp"], 3), "bore_allowance_mm": t["a"], "collar_d_mm": round(2 * t["r_c"], 3), "groove_d_mm": round(seat, 3), "groove_z_mm": [round(z0, 3), round(z1, 3)], "gland_depth_mm": round(t["L"], 3), "gap_mm": 0.0, "rod_offset_mm": round(t["r_bp"] - t["r_c"], 4), "gap_basis": "the lid skirt's bore is the sealing surface; the collar can sit off centre in it by the radial clearance" + (f"; the bore is drawn {t['a']:g} mm (radial) over the size it is meant to print at, and the groove's depth is from the printed bore" if t["a"] else ""), "stretch_pct": round((seat / o["id_mm"] - 1) * 100, 2)})
+        b.walls.append({"feature": f["id"], "what": "base wall behind the collar's O-ring groove", "mm": round(t["r_g"] - e.r_cav, 3), "min_mm": e.mw})
+        b.facts[f["id"]] = fact
+        return
+    if p["type"] == "radial":
+        fr = f["frame"]
+        if not fr:
+            b.problems.append(f"{f['id']}: a radial gland needs a frame (bore axis)")
+            return
+        rod = p["rod_d_mm"]
+        clr = (row["clearance_mm"][0] + row["clearance_mm"][1]) / 2
+        bore_d = rod + clr
+        groove_d = rod + 2 * L
+        pl = plane_at(fr["origin"], fr["normal"], fr.get("xAxis"))
+        o3, n3 = np.asarray(fr["origin"], dtype=float), unit(fr["normal"])
+        hit, wall, _ = e.wall_hit(o3 - n3 * 50, n3)
+        if hit is None or np.linalg.norm(hit - o3) > 0.05:
+            b.problems.append(f"{f['id']}: a radial gland's frame must sit on the outer surface where the bore enters (it is {'off the shell' if hit is None else f'{np.linalg.norm(hit - o3):.2f} mm from it'})")
+            return
+        length = G + 2 * max(e.mw, 1.0)
+        boss_d = groove_d + 2 * max(e.mw, 1.2)
+        need = length - wall
+        if need > 0:
+            b.adds.append((f["id"], prism(pl, Circle(boss_d / 2).face(), -(wall + need), -wall + 0.01)))
+            b.solids.append({"name": f"gland boss {f['id']}", "part": "base", "origin": r3(o3 - n3 * (wall + need)), "axis": r3(n3), "radius": boss_d / 2, "length": need})
+        depth = max(length, wall)
+        b.cuts.append((f["id"], prism(pl, Circle(bore_d / 2).face(), -(depth + 0.01), 1.0)))
+        gz = -depth / 2
+        groove = prism(pl, Circle(groove_d / 2).face(), gz - G / 2, gz + G / 2)
+        b.cuts.append((f["id"], groove))
+        b.marks[f["id"]] = [("*", groove)]
+        b.frames[f["id"]] = frame_of(fr["origin"], fr["normal"], fr.get("xAxis"))
+        # the rod is the sealing surface; it can sit off centre in the bore by the radial clearance, which moves the gland depth by as much
+        fact.update({"rod_d_mm": rod, "bore_d_mm": round(bore_d, 3), "groove_d_mm": round(groove_d, 3), "gland_depth_mm": round(L, 3), "gap_mm": 0.0, "rod_offset_mm": round((bore_d - rod) / 2, 4), "gap_basis": "the rod is the sealing surface, off centre by up to the radial clearance"})
+        b.walls.append({"feature": f["id"], "what": "wall around the gland groove", "mm": round((boss_d - groove_d) / 2 if need > 0 else e.wall, 3), "min_mm": e.mw})
+        b.facts[f["id"]] = fact
+        return
+
+    # face glands: in the base rim at the joint, or a ring at a frame
+    ext = p.get("pressure", "external") == "external"
+    if p.get("at") == "joint":
+        inner_off = p["_inner_offset"]
+        z = e.z_split
+        groove = extrude_region(e.cavity_face(inner_off + G), z - L, L + 0.01) - extrude_region(e.cavity_face(inner_off), z - L - 0.01, L + 0.03)
+        inner_perimeter = sum(ed.length for ed in e.cavity_face(inner_off).outer_wire().edges())
+        b.walls.append({"feature": f["id"], "what": "rim ledge inside the groove", "mm": round(inner_off, 3), "min_mm": e.mw})
+        b.walls.append({"feature": f["id"], "what": "rim ledge outside the groove", "mm": round(e.wall - inner_off - G, 3), "min_mm": e.mw})
+        b.frames[f["id"]] = frame_of([*e.centre, z], [0, 0, 1], [1, 0, 0])
+        # the joint is flat: the lid's face bears on the rim around the groove when its screws close it
+        fact["gap_basis"] = "contact: the lid's flat face bears on the rim (the lid screws close the joint)" if e.scheme == "screws" else "assumed contact: nothing in the design holds the lid down on the rim"
+        fact["gap_assumed"] = e.scheme != "screws"
+    else:
+        fr = f["frame"]
+        pl = plane_at(fr["origin"], fr["normal"], fr.get("xAxis"))
+        # external pressure: groove inner edge on the O-ring ID (+0.5 %); internal: groove outer edge on its OD (-0.5 %)
+        r_in = o["id_mm"] * 1.005 / 2 if ext else (o["id_mm"] + 2 * W) * 0.995 / 2 - G
+        groove = prism(pl, Circle(r_in + G).face(), -L, 0.01) - prism(pl, Circle(r_in).face(), -L - 0.01, 0.02)
+        inner_perimeter = 2 * math.pi * r_in
+        b.frames[f["id"]] = frame_of(fr["origin"], fr["normal"], fr.get("xAxis"))
+        fact["gap_basis"] = "assumed contact: the mating face bears on the gland's face (what presses it, such as a thread's engagement, is not modelled)"
+        fact["gap_assumed"] = True
+    b.cuts.append((f["id"], groove))
+    b.marks[f["id"]] = [("*", groove)]
+    groove_outer = inner_perimeter + 2 * math.pi * G
+    fact.update(
+        {
+            "gland_depth_mm": round(L, 3),
+            "gap_mm": 0.0,
+            "groove_inner_perimeter_mm": round(inner_perimeter, 2),
+            "groove_outer_perimeter_mm": round(groove_outer, 2),
+            "oring_inner_perimeter_mm": round(math.pi * o["id_mm"], 2),
+            "oring_outer_perimeter_mm": round(math.pi * (o["id_mm"] + 2 * W), 2),
+            "pressure": "external" if ext else "internal",
+        }
+    )
+    b.facts[f["id"]] = fact
+
+
+def joint(e: Enclosure, b: Built, f: dict) -> None:
+    b.frames[f["id"]] = frame_of([*e.centre, e.z_split], [0, 0, 1], [1, 0, 0])
+    # the mating face: base faces in the split plane (the bottom of this slab)
+    b.marks[f["id"]] = [("base", Pos(*e.centre, e.z_split) * Box(4 * (e.cav_max[0] - e.cav_min[0] + 40), 4 * (e.cav_max[1] - e.cav_min[1] + 40), 0.04, align=MIN))]
+    fact = {"kind": "joint", "style": e.joint_style, "split_z": round(e.z_split, 3), "scheme": e.scheme}
+    if e.columns:
+        p = f["params"]
+        ins, sc = p["insert"], p["screw"]
+        grip = e.z_top - e.z_cav_top + (e.jc if e.joint_style == "rabbet" else 0.0)
+        fact.update({"columns": [r3([c[0], c[1], e.z_cav_top]) for c in e.columns], "column_d_mm": round(2 * e.rc, 3), "grip_mm": round(grip, 3), "insert": ins, "screw": sc})
+        b.walls.append({"feature": f["id"], "what": "column wall around the insert", "mm": round(e.rc - ins["hole_d_mm"] / 2, 3), "min_mm": max(ins.get("min_wall_mm", 0.0), e.mw)})
+        if sc.get("length_mm") is not None:
+            fact["screw_reach_mm"] = round(sc["length_mm"] - grip, 3)
+            if sc["length_mm"] - grip > ins["hole_depth_mm"]:
+                b.problems.append(f"{f['id']}: a {sc['length_mm']} mm screw through {grip:.2f} mm of lid reaches {sc['length_mm'] - grip:.2f} mm, deeper than the {ins['hole_depth_mm']} mm insert hole (it bottoms out)")
+    b.facts[f["id"]] = fact
+
+
+def annulus(r_in: float, r_out: float, z0: float, z1: float, centre) -> Shape:
+    """A ring about the enclosure's axis from z0 to z1."""
+    cx, cy = centre
+    ring = Cylinder(r_out, z1 - z0, align=MIN)
+    if r_in > 0:
+        ring = ring - Cylinder(r_in, z1 - z0 + 0.02, align=MIN).moved(Location((0, 0, -0.01)))
+    return Pos(cx, cy, z0) * ring
+
+
+def revolved(points: list[tuple[float, float]], start_deg: float, arc_deg: float, centre) -> Shape:
+    """A closed (r, z) profile turned about the enclosure's axis from start_deg through arc_deg."""
+    with BuildSketch(Plane.XZ) as sk:
+        with BuildLine():
+            Polyline(points, close=True)
+        make_face()
+    solid = revolve(sk.sketch.faces()[0], Axis.Z, arc_deg)
+    return Pos(centre[0], centre[1], 0) * (Rot(0, 0, start_deg) * solid)
+
+
+def bayonet_positions(angles: list[float], widths: list[float], clr: float, r: float) -> int:
+    """In how many turned positions a bayonet's lid goes on: each lug must meet a slot wide enough for it
+    (a slot is its lug's width plus the clearance each side). Lugs at angles (deg) on the collar's radius r."""
+    n = len(angles)
+    count = 0
+    for j in range(n):
+        turn = angles[j] - angles[0]
+        ok = True
+        for i in range(n):
+            at = (angles[i] + turn) % 360.0
+            k = next((k for k in range(n) if abs(((angles[k] - at + 180.0) % 360.0) - 180.0) < 1e-6), None)
+            if k is None or widths[i] > widths[k] + 2 * clr + 1e-6:
+                ok = False
+                break
+        count += ok
+    return count
+
+
+def twist_lid(e: Enclosure, b: Built, f: dict) -> None:
+    """The base's collar and the lid's skirt (Enclosure.plan_twist), with the lock: a thread or a bayonet."""
+    t = e.tw
+    if not t:
+        return
+    cx, cy = e.centre
+    z0, top = t["z0"], e.z_cav_top
+    # the base steps in to the collar; the lid's skirt fills the step down to the axial clearance
+    b.base_steps.append((f["id"], annulus(t["r_c"], t["r_o"] + 1.0, z0, top + 0.01, e.centre)))
+    skirt = annulus(t["r_b"], t["r_o"], z0 + t["ax"], top + 0.01, e.centre)
+    b.lid_adds.append((f["id"], skirt))
+    # a lead-in on the skirt's bore so it rides over the O-ring instead of shearing it (about 20°, Parker ORD 5700 §4.3)
+    lead = [(t["r_b"] - 0.01, z0 + t["ax"] - 0.01), (t["r_b"] + 0.35, z0 + t["ax"] - 0.01), (t["r_b"] - 0.01, z0 + t["ax"] + 1.0)]
+    b.lid_cuts.append((f["id"], revolved(lead, 0.0, 360.0, e.centre)))
+    fact = {
+        "kind": "twist_lid",
+        "lock": t["lock"],
+        "collar_d_mm": round(2 * t["r_c"], 3),
+        "bore_d_mm": round(2 * t["r_b"], 3),
+        "outer_d_mm": round(2 * t["r_o"], 3),
+        "collar_z_mm": [round(z0, 3), round(top, 3)],
+        "skirt_wall_mm": round(t["r_o"] - t["r_b"], 3),
+        "lead_in": "0.35 mm over 1.0 mm on the skirt's bore (about 19°)",
+        "base_wall_at_lock_mm": round(t["base_wall_lock"], 3),
+        "printed_bore_d_mm": round(2 * t["r_bp"], 3),
+        "bore_allowance_mm": t["a"],
+        "seal_fit_mm": round(2 * (t["r_bp"] - t["r_c"]), 3),
+        "radial_clearance_mm": t["clr"],
+        "axial_clearance_mm": t["ax"],
+        "print": {
+            "base": "upright, its floor on the bed: the collar's lock faces lean 45° or steeper outward, so they print without supports",
+            "lid": "upside down, its top on the bed: the skirt stands up, and its slot or thread faces lean 45° or steeper, so they print without supports",
+        },
+    }
+    zl0, zl1 = t["zl"]
+    if t["lock"] == "thread":
+        P, d, turns = t["P"], t["d"], t["turns"]
+        crest_w = 0.25 * P
+        base_w = crest_w + 2 * d * math.tan(t["flank"])
+        if base_w >= P:
+            b.problems.append(f"{f['id']}: a {d} mm deep thread with {math.degrees(t['flank']):.0f}° flanks is wider ({base_w:.2f} mm) than its {P} mm pitch")
+            return
+        height = turns * P
+        z_start = zl0 + base_w / 2
+
+        def ridge(r_from: float, r_to: float, dz: float) -> Shape:
+            helix = Helix(pitch=P, height=height, radius=r_from)
+            with BuildSketch(Plane.XZ) as sk:
+                with BuildLine():
+                    Polyline([(r_from - math.copysign(0.2, r_to - r_from), -base_w / 2), (r_to, -crest_w / 2), (r_to, crest_w / 2), (r_from - math.copysign(0.2, r_to - r_from), base_w / 2)], close=True)
+                make_face()
+            return Pos(cx, cy, z_start + dz) * sweep(sk.sketch.faces()[0], path=helix, is_frenet=True)
+
+        # the base's collar steps in again to the thread's root over the thread's zone
+        b.base_steps.append((f["id"], annulus(t["r_root"], t["r_c"] + 0.01, zl0, top + 0.01, e.centre)))
+        base_ridge = ridge(t["r_root"], t["r_major"], 0.0)
+        lid_ridge = ridge(t["r_b"], t["r_crest"], P / 2)
+        b.adds.append((f["id"], base_ridge))
+        b.lid_adds.append((f["id"], lid_ridge))
+        b.marks[f["id"]] = [("base", base_ridge), ("lid", lid_ridge)]
+        fact.update({"pitch_mm": P, "depth_mm": d, "flank_angle_deg": round(math.degrees(t["flank"]), 2), "turns": turns, "major_d_mm": round(2 * t["r_major"], 3), "root_d_mm": round(2 * t["r_root"], 3), "lid_minor_d_mm": round(2 * t["r_crest"], 3), "thread_z_mm": [round(z_start - base_w / 2, 3), round(z_start + height + base_w / 2, 3)]})
+        b.walls.append({"feature": f["id"], "what": "base wall behind the thread's root", "mm": round(t["base_wall_lock"], 3), "min_mm": e.mw})
+        b.walls.append({"feature": f["id"], "what": "lid skirt behind its thread", "mm": round(t["r_o"] - t["r_b"], 3), "min_mm": e.mw})
+    else:
+        d, h, n, twist, clr, ax = t["d"], t["h_lug"], t["n"], t["twist"], t["clr"], t["ax"]
+        r_c = t["r_c"]
+        c_ang = math.degrees(clr / r_c)
+        # the lug: low on the collar, its underside a 45° cone (no supports printed upright)
+        lug = [(r_c - 0.3, zl0), (r_c, zl0), (r_c + d, zl0 + d), (r_c + d, zl1), (r_c - 0.3, zl1)]
+        # the slot in the skirt: open at the bottom where the lug enters, then along the twist; its lower
+        # face parallel to the lug's underside (the face that holds the lid down), the axial clearance between
+        r_slot = r_c + d + clr
+        z_bottom = z0 + t["ax"] - 0.05
+        entry = [(t["r_b"] - 0.5, z_bottom), (r_slot, z_bottom), (r_slot, zl1 + ax), (t["r_b"] - 0.5, zl1 + ax)]
+        along = [(t["r_b"] - 0.5, zl0 - ax), (r_c, zl0 - ax), (r_slot, zl0 + d + clr - ax), (r_slot, zl1 + ax), (t["r_b"] - 0.5, zl1 + ax)]
+        angles = t["angles"]  # the locked lugs' centres (first on +Y, the key when there is one)
+        lugs = []
+        for a, w in zip(angles, t["widths"]):
+            alpha = math.degrees(w / r_c)
+            s_lug = revolved(lug, a - alpha / 2, alpha, e.centre)
+            b.adds.append((f["id"], s_lug))
+            lugs.append(s_lug)
+            b.lid_cuts.append((f["id"], revolved(entry, a - twist - alpha / 2 - c_ang, alpha + 2 * c_ang, e.centre)))
+            b.lid_cuts.append((f["id"], revolved(along, a - twist - alpha / 2 - c_ang, twist + alpha + 2 * c_ang, e.centre)))
+        b.marks[f["id"]] = [("base", s) for s in lugs]
+        keyed = t["widths"][0] != t["w"]
+        fact.update({"lugs": n, "lug_angles_deg": [round(a % 360, 3) for a in angles], "lug_width_mm": t["w"], "lug_widths_mm": t["widths"], "keyed": keyed, "lid_positions": t["positions"], "lug_depth_mm": d, "lug_height_mm": round(h + d, 3), "twist_deg": twist, "lug_z_mm": [round(zl0, 3), round(zl1, 3)], "slot_depth_mm": round(r_slot - t["r_b"], 3), "skirt_behind_slot_mm": round(t["skirt_behind_slot"], 3), "close": f"push the lid down with each lug in its slot's open end{' (the wide lug in the wide slot: it goes on one way only)' if keyed else ''}, then turn it {twist:g}° clockwise seen from above until the lugs stop at the slots' ends"})
+        b.walls.append({"feature": f["id"], "what": "lid skirt behind the bayonet slots", "mm": round(t["skirt_behind_slot"], 3), "min_mm": e.mw})
+        b.walls.append({"feature": f["id"], "what": "base wall of the collar", "mm": round(t["base_wall_lock"], 3), "min_mm": e.mw})
+    b.frames[f["id"]] = frame_of([cx, cy, top], [0, 0, 1], [1, 0, 0])
+    b.facts[f["id"]] = fact
+
+
+KINDS = {"opening": opening, "light_pipe": light_pipe, "window": window, "button": button, "boss": boss, "strap_lugs": strap_lugs, "thread": thread, "seal_gland": seal_gland, "joint": joint, "twist_lid": twist_lid}
+
+
+def plan_joint_gland(e_job: dict, cav_shape: str, cav_size: np.ndarray, wall: float, mw: float) -> None:
+    """Where the joint groove goes: its inner edge offset from the cavity so the O-ring fits (Parker Design Chart 4-2)."""
+    g = next((f for f in e_job["features"] if f["kind"] == "seal_gland" and f["params"].get("at") == "joint" and f["params"]["type"] == "face"), None)
+    if not g:
+        return
+    p = g["params"]
+    row = p["table"]
+    G = (row["width_mm"][0] + row["width_mm"][1]) / 2
+    o = p["oring"]
+    ext = p.get("pressure", "external") == "external"
+    # external pressure: groove inner edge on the O-ring ID (+0.5 %); internal: groove outer edge on its OD (-0.5 %)
+    target = math.pi * o["id_mm"] * 1.005 if ext else math.pi * (o["id_mm"] + 2 * o["w_mm"]) * 0.995 - 2 * math.pi * G
+    base = math.pi * cav_size[0] if cav_shape == "round" else 2 * (cav_size[0] + cav_size[1])
+    off = (target - base) / (2 * math.pi)
+    p["_inner_offset"] = max(off, mw)
+    p["_groove_width"] = G
+
+
+# ---------------------------------------------------------------------------------------------
+# Build
+# ---------------------------------------------------------------------------------------------
+
+
+def load_bodies(job: dict, root: Path) -> list[dict]:
+    out = []
+    for c in job["contents"]:
+        v, f = load_mesh(root / c["glb"], c["matrix"], skip=c.get("skip_nodes"))
+        out.append({"key": c["key"], "label": c.get("label", c["key"]), "V": v, "F": f, "zones": []})
+    return out
+
+
+def build(job: dict, out: Path, root: Path) -> dict:
+    out.mkdir(parents=True, exist_ok=True)
+    (out / "parts").mkdir(exist_ok=True)
+    bodies = load_bodies(job, root)
+    d = job["design"]
+    # the joint groove decides the rim and the screw columns, so it is planned from the cavity first
+    probe = Enclosure({**job, "features": [f for f in job["features"] if f["kind"] != "seal_gland"], "design": {**d, "fasteners": "none"}}, bodies)
+    size = (probe.cav_max - probe.cav_min)[:2] if probe.shape != "round" else np.array([2 * probe.r_cav, 2 * probe.r_cav])
+    plan_joint_gland(job, probe.shape, size, d["wall"], d["min_wall"])
+    e = Enclosure(job, bodies)
+    b = Built()
+    b.problems.extend(e.problems)
+    for c in e.columns:
+        b.solids.append({"name": "lid screw column", "origin": [float(c[0]), float(c[1]), e.z_floor], "axis": [0.0, 0.0, 1.0], "radius": e.rc, "length": e.z_cav_top - e.z_floor})
+
+    # ---- shell, cut at the split plane
+    outer, cavity = e.outer_face(), e.cavity_region()
+    H = e.z_top - e.z_bottom + 2
+    shell = extrude_region(outer, e.z_bottom, e.z_top - e.z_bottom) - extrude_region(cavity, e.z_floor, e.z_cav_top - e.z_floor)
+    lo, hi = e.outer_bounds()
+    span = float(np.max(hi[:2] - lo[:2])) + 4 * (e.rc + e.cw) + 20
+    below = Pos(*e.centre, e.z_split - H) * Box(span, span, H, align=MIN)
+    above = Pos(*e.centre, e.z_split) * Box(span, span, H, align=MIN)
+    base = shell & below
+    lid = shell & above
+    if e.joint_style == "rabbet":
+        w_out = e.w_out
+        tongue = offset(outer, -w_out) - cavity
+        tongue_s = extrude_region(tongue, e.z_split - 0.01, e.lip + 0.01)
+        groove = offset(outer, -(w_out - e.jc)) - cavity
+        groove_s = extrude_region(groove, e.z_split - 0.01, e.lip + e.jc + 0.01)
+        base = base + (tongue_s & shell)
+        lid = lid - groove_s
+        b.walls.append({"feature": e.joint_feature["id"] if e.joint_feature else "joint", "what": "base tongue of the rabbet", "mm": round(e.wall - w_out, 3), "min_mm": e.mw})
+        b.walls.append({"feature": e.joint_feature["id"] if e.joint_feature else "joint", "what": "lid skirt outside the tongue", "mm": round(w_out - e.jc, 3), "min_mm": e.mw})
+    parts: dict[str, Shape] = {"base": base, "lid": lid}
+
+    # ---- features
+    for f in job["features"]:
+        try:
+            KINDS[f["kind"]](e, b, f)
+        except Exception as ex:  # noqa: BLE001 - one feature failing is a finding, not a crash
+            b.problems.append(f"{f['id']}: {type(ex).__name__}: {ex}")
+    for _fid, t in b.base_steps:
+        parts["base"] = parts["base"] - t
+    # a twist lid turns: nothing may cut the side wall where its skirt covers the collar
+    if e.tw:
+        z0, z1 = e.tw["z0"], e.z_cav_top
+        for fid, fr in b.frames.items():
+            fact = b.facts.get(fid, {})
+            if fact.get("kind") not in ("opening", "window", "button"):
+                continue
+            if abs(fr["normal"][2]) > 0.5:
+                continue  # through the floor or the lid, not the side wall
+            sizes = [v[1] for k in ("pocket_mm", "aperture_mm", "size_mm") if isinstance((v := fact.get(k)), list) and len(v) > 1]
+            half = max([*(x / 2 for x in sizes), fact.get("hole_d_mm", 0) / 2, 0.0])
+            lo, hi = fr["origin"][2] - half, fr["origin"][2] + half
+            if hi > z0 - 1e-6 and lo < z1:
+                b.problems.append(f"{fid}: it cuts the side wall at z {lo:.2f}-{hi:.2f}, where the twist lid's skirt covers the collar (from z {z0:.2f}); raise the cavity top or move it down")
+    for _fid, s in b.adds:
+        parts["base"] = parts["base"] + s
+    for _fid, s in b.lid_adds:
+        parts["lid"] = parts["lid"] + s
+    # lid screws: inserts in the columns, clearance holes through the lid
+    if e.columns:
+        jp = e.joint_feature["params"]
+        ins, sc = jp["insert"], jp["screw"]
+        for c in e.columns:
+            parts["base"] = parts["base"] - Pos(c[0], c[1], e.z_cav_top - ins["hole_depth_mm"]) * Cylinder(ins["hole_d_mm"] / 2, ins["hole_depth_mm"] + 0.01, align=MIN)
+            parts["lid"] = parts["lid"] - Pos(c[0], c[1], e.z_split - 0.5) * Cylinder(sc["clearance_d_mm"] / 2, e.z_top - e.z_split + 1, align=MIN)
+    # a face gland at a frame is cut into the surface its frame lies on
+    skin = Compound(parts["base"].faces())
+    for f in job["features"]:
+        if f["kind"] == "seal_gland" and f["params"]["type"] == "face" and f["params"].get("at") != "joint" and f.get("frame"):
+            gap = skin.distance_to(Vector(*f["frame"]["origin"]))
+            if gap > 0.05:
+                b.problems.append(f"{f['id']}: its frame is {gap:.2f} mm off the base's surface; a face gland's frame sits on the face the O-ring seals against")
+    for _fid, t in b.cuts:
+        for k in parts:
+            parts[k] = parts[k] - t
+    for _fid, t in b.base_cuts:
+        parts["base"] = parts["base"] - t
+    for _fid, t in b.lid_cuts:
+        parts["lid"] = parts["lid"] - t
+    # plungers: flanges trimmed to clear the walls as built and what is inside; then checked against the walls exactly
+    if b.plungers:
+        walls = {}
+        for k in ("base", "lid"):
+            if k in parts:
+                vs, ts = parts[k].tessellate(0.01, 0.1)
+                walls[k] = (np.array([[v.X, v.Y, v.Z] for v in vs]), np.array(ts, dtype=np.int64))
+        for fid, spec in b.plungers.items():
+            try:
+                plunger = make_plunger(e, b, fid, spec, walls, bodies)
+            except Exception as ex:  # noqa: BLE001 - one feature failing is a finding, not a crash
+                b.problems.append(f"{fid}: plunger: {type(ex).__name__}: {ex}")
+                continue
+            overlap = {}
+            for k in ("base", "lid"):
+                if k in parts:
+                    common = plunger & parts[k]
+                    overlap[k] = round(sum(x.volume for x in common.solids()) if common is not None else 0.0, 4)
+            b.facts[fid]["wall_overlap_mm3"] = overlap
+            plunger.label = f"plunger_{fid}"
+            b.extra_parts[f"plunger_{fid}"] = plunger
+    for k, s in b.extra_parts.items():
+        parts[k] = s
+    for k in list(parts):
+        solids = parts[k].solids()
+        if not solids:
+            b.problems.append(f"part {k} came out empty")
+            del parts[k]
+            continue
+        parts[k] = Compound(label=k, children=list(solids)) if len(solids) > 1 else solids[0]
+        parts[k].label = k
+        if len(solids) > 1 and not k.startswith("plunger"):
+            b.problems.append(f"part {k} is in {len(solids)} pieces (a feature cut it apart?)")
+
+    # ---- feature faces (signatures) on the parts their tools reach
+    features: dict[str, dict] = {}
+    feature_parts: dict[str, list[str]] = {}
+    shapes = []
+    for fid, marks in b.marks.items():
+        faces: list[Face] = []
+        where: list[str] = []
+        for part_name, tool in marks:
+            for k, part in parts.items():
+                if k.startswith("plunger") or (part_name != "*" and k != part_name):
+                    continue
+                hit = faces_on(part, tool)
+                if hit:
+                    faces += hit
+                    where.append(k)
+        if not faces:
+            b.problems.append(f"{fid}: the feature produced no faces on any part (its tool misses the shell?)")
+            continue
+        features[fid] = signature(faces)
+        feature_parts[fid] = sorted(set(where))
+        s = feature_shape(fid, faces)
+        if s is not None:
+            shapes.append(s)
+
+    # ---- write parts and the body
+    files = []
+    for k, part in sorted(parts.items()):
+        export_step(part, str(out / "parts" / f"{k}.step"))
+        normalise_step(out / "parts" / f"{k}.step")
+        export_gltf(part, str(out / "parts" / f"{k}.glb"), binary=True, linear_deflection=0.02, angular_deflection=0.2)
+        export_stl(part, str(out / "parts" / f"{k}.stl"), tolerance=0.01, angular_tolerance=0.1)
+        m = Mesher()
+        m.add_shape(part, linear_deflection=0.01, angular_deflection=0.1)
+        m.write(str(out / "parts" / f"{k}.3mf"))
+        repack_zip(out / "parts" / f"{k}.3mf")
+        files.append(k)
+    # window covers: each its own STEP, GLB and a DXF outline for cutting, in the cover's frame
+    covers = {}
+    if b.covers:
+        (out / "covers").mkdir(exist_ok=True)
+    for fid, c in sorted(b.covers.items()):
+        name = f"cover_{fid}"
+        solid = c["solid"]
+        solid.label = name
+        export_step(solid, str(out / "covers" / f"{name}.step"))
+        normalise_step(out / "covers" / f"{name}.step")
+        export_gltf(solid, str(out / "covers" / f"{name}.glb"), binary=True, linear_deflection=0.01, angular_deflection=0.1)
+        dxf = ExportDXF(unit=Unit.MM)
+        dxf.add_shape(c["outline"])
+        dxf.write(str(out / "covers" / f"{name}.dxf"))
+        normalise_dxf(out / "covers" / f"{name}.dxf")
+        covers[fid] = {"part": name, "shape": c["shape"], "size_mm": c["size_mm"], "thickness_mm": c["thickness_mm"], "material": c["material"], "volume_mm3": round(solid.volume, 4), "frame": {"origin": [0.0, 0.0, 0.0], "normal": [0.0, 0.0, 1.0], "xAxis": [1.0, 0.0, 0.0]}}
+    body = Compound(label=job["name"], children=[*(parts[k] for k in sorted(parts)), *shapes])
+    export_step(body, str(out / "body.step"))
+    normalise_step(out / "body.step")
+    export_gltf(Compound(label=job["name"], children=[parts[k] for k in sorted(parts)]), str(out / "body.glb"), binary=True, linear_deflection=0.02, angular_deflection=0.2)
+    try:
+        write_section(parts, e, out / "section.svg", bodies, {f"cover_{k}": c["placed"] for k, c in b.covers.items()})
+    except Exception as ex:  # noqa: BLE001 - the render is optional
+        b.problems.append(f"section render skipped: {type(ex).__name__}: {ex}")
+
+    # ---- fit: what goes inside against the walls
+    for body_ in bodies:
+        body_["zones"] = b.zones.get(body_["key"], [])
+    wall_parts = {k: load_mesh(out / "parts" / f"{k}.glb") for k in parts if not k.startswith("plunger")}
+    fit = analyse(wall_parts, bodies, cavity_spec(e, b), d["resolution"], e.clr)
+    # plungers against what is inside (against the walls they are checked exactly, above)
+    fit["plungers"] = analyse_plungers([plunger_spec(fid, b, out / "parts" / f"plunger_{fid}.glb", fit["resolution_mm"]) for fid in b.plungers if f"plunger_{fid}" in parts], bodies, fit["resolution_mm"], e.clr)
+    for entry in fit["plungers"]:
+        overlap = b.facts[entry["feature"]].get("wall_overlap_mm3", {})
+        entry["wall_overlap_mm3"] = overlap
+        if any(v > 1e-3 for v in overlap.values()):
+            entry["status"] = "collision"
+
+    volumes = {k: round(parts[k].volume, 3) for k in sorted(parts)}
+    shell_box = Compound(children=[parts[k] for k in parts if not k.startswith("plunger")]).bounding_box()
+    digest = hashlib.sha256(GENERATOR.read_bytes() + (HERE / "fit.py").read_bytes() + json.dumps(job, sort_keys=True).encode()).hexdigest()
+    manifest = {
+        "artifact": "body",
+        "tool": TOOL,
+        "toolVersion": bd.__version__,
+        "generator": "@protoboardai/ext-enclosure-cad py/enclosure_cad.py",
+        "sourceDigest": digest,
+        "units": "mm",
+        "features": features,
+        "volume_mm3": round(sum(volumes.values()), 3),
+        "bodies": volumes,
+        "frames": b.frames,
+        "process": job["process"],
+        "material": job.get("material"),
+    }
+    (out / "body.manifest.json").write_text(json.dumps(manifest, indent=2) + "\n")
+    report = {
+        "schema": "protoboard.enclosure-cad.report/v0",
+        "module": job["module"],
+        "name": job["name"],
+        "toolVersion": bd.__version__,
+        "sourceDigest": digest,
+        "inputsDigest": job["inputsDigest"],
+        "cavity": cavity_spec(e, b),
+        "outer": {"min": r3(e.outer_bounds()[0]), "max": r3(e.outer_bounds()[1])},
+        "overall": {"min": r3([shell_box.min.X, shell_box.min.Y, shell_box.min.Z]), "max": r3([shell_box.max.X, shell_box.max.Y, shell_box.max.Z])},
+        "levels": {"bottom": round(e.z_bottom, 3), "floor": round(e.z_floor, 3), "split": round(e.z_split, 3), "cavity_top": round(e.z_cav_top, 3), "top": round(e.z_top, 3)},
+        "parts": {k: {"volume_mm3": volumes[k], "printed": job["process"] == "print"} for k in files},
+        "features": {fid: {**b.facts.get(fid, {}), "frame": b.frames.get(fid), "parts": feature_parts.get(fid, []), "signature": features.get(fid)} for fid in sorted(set(b.facts) | set(b.frames))},
+        "walls": b.walls,
+        "covers": covers,
+        "problems": b.problems,
+        "fit": fit,
+    }
+    (out / "report.json").write_text(json.dumps(report, indent=2) + "\n")
+    return report
+
+
+def cavity_spec(e: Enclosure, b: Built) -> dict:
+    """The cavity and the solids standing in it, for the exact part of the fit analysis.
+
+    The side walls belong to the base up to `side_top` (the split, or the top of
+    a rabbet's tongue) and to the lid above it; the floor to the base, the
+    ceiling to the lid.
+    """
+    spec = {"shape": e.shape, "min": r3(e.cav_min), "max": r3(e.cav_max)}
+    if e.shape == "round":
+        spec.update({"centre": r3(e.centre), "radius": round(e.r_cav, 3)})
+    spec["split_z"] = round(e.z_split, 3)
+    spec["side_top"] = round(e.z_split + (e.lip if e.joint_style == "rabbet" else 0.0), 3)
+    spec["solids"] = [{**s, "origin": r3(s["origin"]), "radius": round(s["radius"], 4), "length": round(s["length"], 4)} for s in b.solids]
+    return spec
+
+
+def plunger_spec(fid: str, b: Built, glb: Path, res: float) -> dict:
+    """A plunger for the fit: its mesh, and its tip (where it meets the switch by design) as a zone."""
+    fact = b.facts[fid]
+    pl = b.plungers[fid]["plane"]
+    n = [pl.z_dir.X, pl.z_dir.Y, pl.z_dir.Z]
+    v, f = load_mesh(glb)
+    zone = {"centre": fact["tip"], "axis": r3(n), "radius": fact["shaft_d_mm"] / 2 + 0.01, "z": [-0.01, fact["gap_mm"] + res]}
+    return {"key": f"plunger_{fid}", "feature": fid, "V": v, "F": f, "zones": [zone]}
+
+
+def repack_zip(path: Path) -> None:
+    """lib3mf writes ZIP64 containers with the time in each entry; repack as a plain ZIP with fixed times (reruns are byte-identical)."""
+    import zipfile
+
+    with zipfile.ZipFile(path) as z:
+        entries = [(i.filename, z.read(i.filename)) for i in z.infolist()]
+    # lib3mf stamps random production-extension UUIDs; derive them from the part name and their order instead
+    count = iter(range(1 << 30))
+
+    def uuid(_m: re.Match) -> str:
+        h = hashlib.sha256(f"{path.stem}:{next(count)}".encode()).hexdigest()
+        return f'p:UUID="{h[:8]}-{h[8:12]}-4{h[13:16]}-8{h[17:20]}-{h[20:32]}"'
+
+    entries = [(n, re.sub(rb'p:UUID="[0-9a-fA-F-]{36}"', lambda m: uuid(m).encode(), d) if n.endswith(".model") else d) for n, d in entries]
+    with zipfile.ZipFile(path, "w", compression=zipfile.ZIP_DEFLATED) as z:
+        for name, data in entries:
+            info = zipfile.ZipInfo(name, date_time=(1980, 1, 1, 0, 0, 0))
+            info.compress_type = zipfile.ZIP_DEFLATED
+            info.external_attr = 0o644 << 16
+            z.writestr(info, data)
+
+
+def normalise_step(path: Path) -> None:
+    """OCC stamps the time into FILE_NAME; fix it so reruns are byte-identical."""
+    path.write_text(re.sub(r"FILE_NAME\('([^']*)','[^']*'", lambda m: f"FILE_NAME('{m.group(1)}','{FIXED_TIME}'", path.read_text(), count=1))
+
+
+def normalise_dxf(path: Path) -> None:
+    """ezdxf stamps the time and random GUIDs into the header; fix them, so reruns are byte-identical."""
+    lines = path.read_text(encoding="utf-8").split("\n")
+    fixed = {"$TDCREATE": "2451545.0", "$TDUCREATE": "2451545.0", "$TDUPDATE": "2451545.0", "$TDUUPDATE": "2451545.0", "$TDINDWG": "0.0", "$FINGERPRINTGUID": "{00000000-0000-0000-0000-000000000000}", "$VERSIONGUID": "{00000000-0000-0000-0000-000000000000}"}
+    for i, l in enumerate(lines[:-2]):
+        if l.strip() in fixed:
+            lines[i + 2] = fixed[l.strip()]
+    # ezdxf's own "<version> @ <timestamp>" marks
+    lines = [re.sub(r"^(\d+\.\d+\.\d+) @ \d{4}-\d\d-\d\dT[\d:.+]+$", r"\1", l) for l in lines]
+    path.write_text("\n".join(lines), encoding="utf-8")
+
+
+def write_section(parts: dict[str, Shape], e: Enclosure, path: Path, bodies: list[dict] | None = None, covers: dict[str, Shape] | None = None) -> None:
+    """A section on the XZ plane through the cavity centre, as SVG: the case's parts and covers cut and filled,
+    and what goes inside (the contents' meshes) cut as outlines, each in its own colour, with a legend and a
+    millimetre scale. +Z (towards the lid) is up."""
+    y0 = float(e.centre[1])
+    pl = Plane(origin=Vector(0, y0, 0), x_dir=Vector(1, 0, 0), z_dir=Vector(0, -1, 0))
+    S = 8.0  # px per mm
+    polys: list[tuple[str, list[list[tuple[float, float]]], str]] = []  # (label, rings in (x, z), fill)
+    fills = {"base": "#b8c4d6", "lid": "#d3d9e2"}
+
+    def rings_of(face) -> list[list[tuple[float, float]]]:
+        out = []
+        for w in [face.outer_wire(), *face.inner_wires()]:
+            pts = [w.position_at(t) for t in np.linspace(0, 1, 600)]
+            ring = [(round(p.X, 3), round(p.Z, 3)) for p in pts]
+            # the wire starts wherever the kernel put its first vertex: start at the least point, run one way
+            k = ring.index(min(ring))
+            ring = ring[k:] + ring[:k]
+            if len(ring) > 2 and ring[1] > ring[-1]:
+                ring = [ring[0]] + ring[1:][::-1]
+            out.append(ring)
+        return out
+
+    for k, part in sorted({**parts, **(covers or {})}.items()):
+        try:
+            sec = part.intersect(Pos(0, y0, 0) * Box(1000, 1e-3, 1000))
+        except Exception:  # noqa: BLE001 - one part that does not cut is left out of the drawing
+            continue
+        if sec is None:
+            continue
+        # the slab's two big faces are the same outline: one of them
+        faces = sorted((f for f in (sec.faces() if hasattr(sec, "faces") else []) if f.normal_at().Y > 0.9), key=lambda f: (round(f.center().X, 3), round(f.center().Z, 3), round(f.area, 3)))
+        if not faces:
+            continue
+        label = k.replace("_", " ")
+        fill = fills.get(k, "#9fd3f0" if k.startswith("cover") else "#e6c79c")
+        polys.append((label, [r for f in faces for r in rings_of(f)], fill))
+    # contents: triangle meshes cut by the plane
+    segs: list[tuple[str, list[tuple[float, float, float, float]]]] = []
+    for body in bodies or []:
+        V, F = body["V"], body["F"]
+        if not len(F):
+            continue
+        d = V[:, 1] - y0
+        F = np.asarray(F, dtype=np.int64)
+        D = d[F]
+        pos = D > 0
+        cut = ~(pos.all(axis=1) | (~pos).all(axis=1))
+        Fc, Dc = F[cut], D[cut]
+        P = [[], []]
+        for e0, e1 in ((0, 1), (1, 2), (2, 0)):
+            m = (Dc[:, e0] > 0) != (Dc[:, e1] > 0)
+            t = np.where(m, Dc[:, e0] / np.where(m, Dc[:, e0] - Dc[:, e1], 1.0), 0.0)
+            q = V[Fc[:, e0]] + t[:, None] * (V[Fc[:, e1]] - V[Fc[:, e0]])
+            P[0].append(np.where(m[:, None], q[:, [0, 2]], np.nan))
+        pts = np.stack(P[0], axis=1)  # (n, 3 edges, 2)
+        out = []
+        for row in pts:
+            ok = row[~np.isnan(row[:, 0])]
+            if len(ok) >= 2:
+                out.append((float(ok[0][0]), float(ok[0][1]), float(ok[1][0]), float(ok[1][1])))
+        if out:
+            segs.append((body.get("label", body["key"]), out))
+    xs = [x for _, rs, _ in polys for r in rs for x, _ in r] + [v for _, ss in segs for s_ in ss for v in (s_[0], s_[2])]
+    zs = [z for _, rs, _ in polys for r in rs for _, z in r] + [v for _, ss in segs for s_ in ss for v in (s_[1], s_[3])]
+    if not xs:
+        return
+    x0, x1, z0, z1 = min(xs) - 2, max(xs) + 2, min(zs) - 2, max(zs) + 2
+    W, H = (x1 - x0) * S, (z1 - z0) * S
+    legend_h = 16 * (len(polys) + len(segs)) + 30
+    X = lambda x: (x - x0) * S  # noqa: E731
+    Z = lambda z: (z1 - z) * S  # noqa: E731
+    colors = ["#d94e00", "#1f6fb2", "#2e8b57", "#8e44ad", "#b8860b", "#c0392b", "#16a085", "#555555"]
+    el = [f'<svg xmlns="http://www.w3.org/2000/svg" viewBox="0 0 {W:.1f} {H + legend_h:.1f}" width="{W:.0f}" height="{H + legend_h:.0f}" font-family="sans-serif" font-size="11">', f'<rect width="100%" height="100%" fill="#fff"/>']
+    for label, rings, fill in polys:
+        dpath = " ".join("M" + " L".join(f"{X(x):.2f},{Z(z):.2f}" for x, z in r) + " Z" for r in rings)
+        el.append(f'<path d="{dpath}" fill="{fill}" fill-rule="evenodd" stroke="#333" stroke-width="0.8"/>')
+    for i, (label, ss) in enumerate(segs):
+        col = colors[i % len(colors)]
+        dpath = " ".join(f"M{X(a):.2f},{Z(bz):.2f} L{X(c):.2f},{Z(dz):.2f}" for a, bz, c, dz in ss)
+        el.append(f'<path d="{dpath}" fill="none" stroke="{col}" stroke-width="1.2" stroke-linecap="round"/>')
+    y = H + 18
+    for label, _, fill in polys:
+        el.append(f'<rect x="8" y="{y - 9}" width="14" height="10" fill="{fill}" stroke="#333" stroke-width="0.6"/><text x="28" y="{y}">{label} (cut)</text>')
+        y += 16
+    for i, (label, _) in enumerate(segs):
+        el.append(f'<line x1="8" x2="22" y1="{y - 4}" y2="{y - 4}" stroke="{colors[i % len(colors)]}" stroke-width="2"/><text x="28" y="{y}">{label}</text>')
+        y += 16
+    # 5 mm scale bar
+    el.append(f'<line x1="{W - 8 - 5 * S:.1f}" x2="{W - 8:.1f}" y1="{H + 14}" y2="{H + 14}" stroke="#000" stroke-width="2"/><text x="{W - 8:.1f}" y="{H + 28}" text-anchor="end">5 mm</text><text x="{W - 8:.1f}" y="{H + 42}" text-anchor="end">section at y = {y0:g} mm, +Z up</text>')
+    el.append("</svg>")
+    path.write_text("\n".join(el) + "\n", encoding="utf-8")
+
+
+def main() -> None:
+    mode = sys.argv[1]
+    if mode == "build":
+        job = json.loads(Path(sys.argv[2]).read_text())
+        out = Path(sys.argv[3])
+        root = Path(sys.argv[sys.argv.index("--root") + 1]) if "--root" in sys.argv else Path.cwd()
+        r = build(job, out, root)
+        print(json.dumps({"name": r["name"], "problems": r["problems"], "fit": {"bodies": r["fit"]["bodies"], "walls": r["fit"]["walls"]}}))
+    elif mode == "fit":
+        spec = json.loads(sys.stdin.read() if sys.argv[2] == "-" else Path(sys.argv[2]).read_text())
+        root = Path(spec["root"])
+        meshes = {k: load_mesh(root / p, node=k if spec.get("by_node") else None) for k, p in {**spec["parts"], **{x["key"]: x["glb"] for x in spec.get("plungers", [])}}.items()}
+        bodies = []
+        for c in spec["contents"]:
+            v, f = load_mesh(root / c["glb"], c["matrix"], skip=c.get("skip_nodes"))
+            bodies.append({"key": c["key"], "label": c.get("label", c["key"]), "V": v, "F": f, "zones": spec.get("zones", {}).get(c["key"], [])})
+        fit = analyse({k: meshes[k] for k in spec["parts"]}, bodies, spec["cavity"], spec["resolution"], spec["clearance"])
+        plungers = [{"key": x["key"], "feature": x["feature"], "V": meshes[x["key"]][0], "F": meshes[x["key"]][1], "zones": x.get("zones", [])} for x in spec.get("plungers", [])]
+        fit["plungers"] = analyse_plungers(plungers, bodies, fit["resolution_mm"], spec["clearance"])
+        print(json.dumps(fit))
+    else:
+        raise SystemExit(f"unknown mode {mode}")
+
+
+if __name__ == "__main__":
+    main()