@tscircuit/copper-pour-solver 0.0.25 → 0.0.26

package/lib/solvers/copper-pour/generate-brep.ts

@@ -1,52 +1,59 @@
+import Flatten from "@flatten-js/core"
 import type { BRepShape } from "circuit-json"
-import type { CopperPourIsland, PolygonRing } from "./manifold-geometry-adapter"
-
-const signedArea = (ring: PolygonRing) => {
-  let area = 0
-  for (let i = 0; i < ring.length; i++) {
-    const current = ring[i]!
-    const next = ring[(i + 1) % ring.length]!
-    area += current.x * next.y - next.x * current.y
-  }
-  return area / 2
-}
-
-const ensureAreaSign = (
-  ring: PolygonRing,
-  desiredSign: "positive" | "negative",
-) => {
-  const area = signedArea(ring)
-  const shouldReverse =
-    (desiredSign === "positive" && area < 0) ||
-    (desiredSign === "negative" && area > 0)
-  return shouldReverse ? [...ring].reverse() : ring
-}
-
-const ringToVertices = (ring: PolygonRing) =>
-  ring.map((point) => ({
-    x: point.x,
-    y: point.y,
-  }))
 
-export const generateBRep = (pourIslands: CopperPourIsland[]): BRepShape[] => {
+const faceToVertices = (face: Flatten.Face) =>
+  face.edges.map((e) => {
+    const pt: { x: number; y: number; bulge?: number } = {
+      x: e.start.x,
+      y: e.start.y,
+    }
+    if (e.isArc) {
+      const bulge = Math.tan((e.shape as Flatten.Arc).sweep / 4)
+      if (Math.abs(bulge) > 1e-9) {
+        pt.bulge = bulge
+      }
+    }
+    return pt
+  })
+
+export const generateBRep = (
+  pourPolygons: Flatten.Polygon | Flatten.Polygon[],
+): BRepShape[] => {
   const brep_shapes: BRepShape[] = []
 
-  for (const island of pourIslands) {
-    if (island.outerRing.length < 3) continue
-
-    // circuit-json BRep uses implicit closure. Keep the previous renderer-facing
-    // winding: outer rings have negative signed area, holes have positive area.
-    const outerRing = ensureAreaSign(island.outerRing, "negative")
-    const innerRings = island.innerRings
-      .filter((ring) => ring.length >= 3)
-      .map((ring) => ensureAreaSign(ring, "positive"))
-
-    brep_shapes.push({
-      outer_ring: { vertices: ringToVertices(outerRing) },
-      inner_rings: innerRings.map((ring) => ({
-        vertices: ringToVertices(ring),
-      })),
-    })
+  const polygons = Array.isArray(pourPolygons) ? pourPolygons : [pourPolygons]
+
+  for (const p of polygons) {
+    const islands = p.splitToIslands()
+
+    for (const island of islands) {
+      if (island.isEmpty()) continue
+
+      const faces = [...island.faces] as Flatten.Face[]
+      const outer_face_ccw = faces.find(
+        (f) => f.orientation() === Flatten.ORIENTATION.CCW,
+      )
+      const inner_faces_cw = faces.filter(
+        (f) => f.orientation() === Flatten.ORIENTATION.CW,
+      )
+
+      if (!outer_face_ccw) continue
+
+      // BRep requires outer ring to be CW and inner rings to be CCW.
+      // Flatten-js provides outer face as CCW and inner faces as CW.
+      // We need to reverse them.
+      outer_face_ccw.reverse()
+      const outer_ring_vertices = faceToVertices(outer_face_ccw)
+      const inner_rings = inner_faces_cw.map((f) => {
+        f.reverse()
+        return { vertices: faceToVertices(f) }
+      })
+
+      brep_shapes.push({
+        outer_ring: { vertices: outer_ring_vertices },
+        inner_rings,
+      })
+    }
   }
 
   return brep_shapes

package/lib/solvers/copper-pour/get-board-polygon.ts

@@ -1,12 +1,18 @@
 import type { InputPourRegion } from "lib/types"
-import type { PolygonRing } from "./manifold-geometry-adapter"
-import { normalizeRing } from "./manifold-geometry-adapter"
+import Flatten from "@flatten-js/core"
 
-export const getBoardPolygon = (region: InputPourRegion): PolygonRing => {
+export const getBoardPolygon = (region: InputPourRegion): Flatten.Polygon => {
   const board_edge_margin = region.board_edge_margin ?? 0
 
   if (region.outline && region.outline.length > 0) {
-    return normalizeRing(region.outline, "getBoardPolygon.outline")
+    const polygon = new Flatten.Polygon(
+      region.outline.map((p) => Flatten.point(p.x, p.y)),
+    )
+    // Ensure polygon is CCW for consistent boolean operations
+    if (polygon.orientation() === Flatten.ORIENTATION.CW) {
+      polygon.reverse()
+    }
+    return polygon
   }
 
   const { bounds } = region
@@ -18,13 +24,15 @@ export const getBoardPolygon = (region: InputPourRegion): PolygonRing => {
   }
 
   if (newBounds.minX >= newBounds.maxX || newBounds.minY >= newBounds.maxY) {
-    return []
+    return new Flatten.Polygon()
   }
 
-  return [
-    { x: newBounds.minX, y: newBounds.minY },
-    { x: newBounds.maxX, y: newBounds.minY },
-    { x: newBounds.maxX, y: newBounds.maxY },
-    { x: newBounds.minX, y: newBounds.maxY },
-  ]
+  return new Flatten.Polygon(
+    new Flatten.Box(
+      newBounds.minX,
+      newBounds.minY,
+      newBounds.maxX,
+      newBounds.maxY,
+    ).toPoints(),
+  )
 }

package/lib/solvers/copper-pour/process-obstacles.ts

@@ -1,3 +1,4 @@
+import Flatten from "@flatten-js/core"
 import type { Point } from "@tscircuit/math-utils"
 import type {
   InputCircularPad,
@@ -6,14 +7,10 @@ import type {
   InputRectPad,
   InputTracePad,
 } from "lib/types"
-import {
-  normalizeRing,
-  offsetPolygon,
-  type PolygonRing,
-} from "./manifold-geometry-adapter"
+import { circleToPolygon } from "./circle-to-polygon"
 
 interface ProcessedObstacles {
-  polygonsToSubtract: PolygonRing[]
+  polygonsToSubtract: Flatten.Polygon[]
 }
 
 const isRectPad = (pad: InputPad): pad is InputRectPad => pad.shape === "rect"
@@ -24,34 +21,6 @@ const isCircularPad = (pad: InputPad): pad is InputCircularPad =>
 const isPolygonPad = (pad: InputPad): pad is InputPolygonPad =>
   pad.shape === "polygon"
 
-const circleToPolygon = (
-  center: Point,
-  radius: number,
-  numSegments = 32,
-): PolygonRing => {
-  const points: PolygonRing = []
-  for (let i = 0; i < numSegments; i++) {
-    const angle = (i / numSegments) * 2 * Math.PI
-    points.push({
-      x: center.x + radius * Math.cos(angle),
-      y: center.y + radius * Math.sin(angle),
-    })
-  }
-  return points
-}
-
-const boxToPolygon = (
-  minX: number,
-  minY: number,
-  maxX: number,
-  maxY: number,
-): PolygonRing => [
-  { x: minX, y: minY },
-  { x: maxX, y: minY },
-  { x: maxX, y: maxY },
-  { x: minX, y: maxY },
-]
-
 export const processObstaclesForPour = (
   pads: InputPad[],
   pourConnectivityKey: string,
@@ -63,7 +32,7 @@ export const processObstaclesForPour = (
   },
   boardOutline?: Point[],
 ): ProcessedObstacles => {
-  const polygonsToSubtract: PolygonRing[] = []
+  const polygonsToSubtract: Flatten.Polygon[] = []
 
   const { padMargin, traceMargin, board_edge_margin, cutoutMargin } = margins
 
@@ -73,10 +42,13 @@ export const processObstaclesForPour = (
     board_edge_margin &&
     board_edge_margin > 0
   ) {
-    const vertices = normalizeRing(
-      boardOutline,
-      "processObstacles.boardOutline",
+    const boardPoly = new Flatten.Polygon(
+      boardOutline.map((p) => Flatten.point(p.x, p.y)),
     )
+    if (boardPoly.area() < 0) {
+      boardPoly.reverse()
+    }
+    const vertices = boardPoly.vertices
 
     // Add clearance shapes at vertices
     for (let i = 0; i < vertices.length; i++) {
@@ -86,21 +58,21 @@ export const processObstaclesForPour = (
 
       if (!p1 || !p2 || !p3) continue
 
-      const v1 = { x: p2.x - p1.x, y: p2.y - p1.y }
-      const v2 = { x: p3.x - p2.x, y: p3.y - p2.y }
-      const crossProduct = v1.x * v2.y - v1.y * v2.x
+      const v1 = new Flatten.Vector(p1, p2)
+      const v2 = new Flatten.Vector(p2, p3)
+      const crossProduct = v1.cross(v2)
 
-      polygonsToSubtract.push(circleToPolygon(p2, board_edge_margin))
+      const circle = new Flatten.Circle(p2, board_edge_margin)
+      polygonsToSubtract.push(circleToPolygon(circle))
 
       if (crossProduct < 0) {
-        polygonsToSubtract.push(
-          boxToPolygon(
-            p2.x - board_edge_margin,
-            p2.y - board_edge_margin,
-            p2.x + board_edge_margin,
-            p2.y + board_edge_margin,
-          ),
+        const box = new Flatten.Box(
+          p2.x - board_edge_margin,
+          p2.y - board_edge_margin,
+          p2.x + board_edge_margin,
+          p2.y + board_edge_margin,
         )
+        polygonsToSubtract.push(new Flatten.Polygon(box.toPoints()))
       }
     }
 
@@ -139,7 +111,9 @@ export const processObstaclesForPour = (
         y: centerY + p.x * sinAngle + p.y * cosAngle,
       }))
 
-      polygonsToSubtract.push(rotatedCorners)
+      polygonsToSubtract.push(
+        new Flatten.Polygon(rotatedCorners.map((p) => Flatten.point(p.x, p.y))),
+      )
     }
   }
 
@@ -156,23 +130,24 @@ export const processObstaclesForPour = (
 
     if (isCircularPad(pad)) {
       const margin = isHoleOrCutout ? (cutoutMargin ?? 0) : padMargin
-      polygonsToSubtract.push(
-        circleToPolygon({ x: pad.x, y: pad.y }, pad.radius + margin),
+      const circle = new Flatten.Circle(
+        new Flatten.Point(pad.x, pad.y),
+        pad.radius + margin,
       )
+      polygonsToSubtract.push(circleToPolygon(circle))
       continue
     }
 
     if (isRectPad(pad)) {
       const margin = isHoleOrCutout ? (cutoutMargin ?? 0) : padMargin
       const { bounds } = pad
-      polygonsToSubtract.push(
-        boxToPolygon(
-          bounds.minX - margin,
-          bounds.minY - margin,
-          bounds.maxX + margin,
-          bounds.maxY + margin,
-        ),
+      const b = new Flatten.Box(
+        bounds.minX - margin,
+        bounds.minY - margin,
+        bounds.maxX + margin,
+        bounds.maxY + margin,
       )
+      polygonsToSubtract.push(new Flatten.Polygon(b.toPoints()))
       continue
     }
 
@@ -191,24 +166,67 @@ export const processObstaclesForPour = (
 
       if (uniquePoints.length < 3) continue
 
-      const polygon = normalizeRing(uniquePoints, "processObstacles.polygonPad")
-      if (polygon.length < 3) continue
+      const polygon = new Flatten.Polygon(
+        uniquePoints.map((p) => Flatten.point(p.x, p.y)),
+      )
+
+      if (Math.abs(polygon.area()) < 1e-9) continue
 
       if (margin <= 0) {
         polygonsToSubtract.push(polygon)
         continue
       }
 
-      polygonsToSubtract.push(...offsetPolygon(polygon, margin))
+      // Ensure polygon is CCW for consistent normal direction.
+      // In flatten-js, CCW corresponds to a negative area.
+      if (polygon.area() > 0) {
+        polygon.reverse()
+      }
+
+      const offsetLines: Flatten.Line[] = []
+      const polygonVertices = polygon.vertices
+      for (let i = 0; i < polygonVertices.length; i++) {
+        const p1 = polygonVertices[i]!
+        const p2 = polygonVertices[(i + 1) % polygonVertices.length]!
+
+        const segment = Flatten.segment(p1, p2)
+
+        if (segment.length === 0) continue
+
+        const line = Flatten.line(segment.start, segment.end)
+
+        // For a CCW polygon, the normal (rotated +90deg, i.e. "left") points inward.
+        // We must translate outward, so we use a negative margin.
+        const norm = line.norm
+        const offsetLine = line.translate(norm.multiply(-margin))
+        offsetLines.push(offsetLine)
+      }
+
+      const newPolygonPoints: Flatten.Point[] = []
+      for (let i = 0; i < offsetLines.length; i++) {
+        const line1 = offsetLines[i]!
+        const line2 = offsetLines[(i + 1) % offsetLines.length]!
+
+        const ip = line1.intersect(line2)
+        if (ip.length > 0) {
+          newPolygonPoints.push(ip[0]!)
+        }
+      }
+
+      if (newPolygonPoints.length >= 3) {
+        polygonsToSubtract.push(new Flatten.Polygon(newPolygonPoints))
+      }
       continue
     }
 
     if (isTracePad(pad)) {
       // Add circles for each vertex
       for (const segment of pad.segments) {
-        polygonsToSubtract.push(
-          circleToPolygon(segment, pad.width / 2 + traceMargin),
+        const circle = new Flatten.Circle(
+          new Flatten.Point(segment.x, segment.y),
+          pad.width / 2 + traceMargin,
         )
+        polygonsToSubtract.push(circleToPolygon(circle))
       }
 
       // Add rectangles for each segment
@@ -247,7 +265,11 @@ export const processObstaclesForPour = (
           y: centerY + p.x * sinAngle + p.y * cosAngle,
         }))
 
-        polygonsToSubtract.push(rotatedCorners)
+        polygonsToSubtract.push(
+          new Flatten.Polygon(
+            rotatedCorners.map((p) => Flatten.point(p.x, p.y)),
+          ),
+        )
       }
     }
   }

package/package.json

@@ -1,7 +1,7 @@
 {
   "name": "@tscircuit/copper-pour-solver",
   "main": "dist/index.js",
-  "version": "0.0.25",
+  "version": "0.0.26",
   "scripts": {
     "format": "biome format . --write",
     "format:check": "biome format .",
@@ -26,8 +26,5 @@
   },
   "peerDependencies": {
     "typescript": "^5"
-  },
-  "dependencies": {
-    "manifold-3d": "^3.4.1"
   }
 }

package/tests/__snapshots__/2-layers-bottom.snap.svg

@@ -1 +1 @@
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