@vcad/mcp 0.9.4-main.39 → 0.9.4-main.41

package/README.md

@@ -6,4 +6,4 @@ vcad's MCP server as a self-contained bundle (server + BRep kernel WASM).
 { "mcpServers": { "vcad": { "command": "npx", "args": ["-y", "@vcad/mcp"] } } }
 ```
 
-Built from 08cd95d4487b522463d0a1a3b58b84935a1f7d08 at 2026-07-26T13:56:33.334Z. Source: https://github.com/ecto/vcad
+Built from b00f071e4b839c6448769107ed84182597d763ed at 2026-07-26T14:41:39.682Z. Source: https://github.com/ecto/vcad

package/index.mjs

@@ -165,6 +165,7 @@ __export(vcad_kernel_wasm_exports, {
   estimate_cost_for_process: () => estimate_cost_for_process,
   eulerXyzDegToQuat: () => eulerXyzDegToQuat,
   evalVcadSource: () => evalVcadSource,
+  evalVcadSourceParametric: () => evalVcadSourceParametric,
   evalVcadSourceWithModules: () => evalVcadSourceWithModules,
   evaluateDocument: () => evaluateDocument,
   evaluateSheetMetalChain: () => evaluateSheetMetalChain,
@@ -1777,6 +1778,17 @@ function evalVcadSource(source) {
   }
   return takeFromExternrefTable0(ret[0]);
 }
+function evalVcadSourceParametric(source, modules_json) {
+  const ptr0 = passStringToWasm0(source, wasm.__wbindgen_malloc, wasm.__wbindgen_realloc);
+  const len0 = WASM_VECTOR_LEN;
+  var ptr1 = isLikeNone(modules_json) ? 0 : passStringToWasm0(modules_json, wasm.__wbindgen_malloc, wasm.__wbindgen_realloc);
+  var len1 = WASM_VECTOR_LEN;
+  const ret = wasm.evalVcadSourceParametric(ptr0, len0, ptr1, len1);
+  if (ret[2]) {
+    throw takeFromExternrefTable0(ret[1]);
+  }
+  return takeFromExternrefTable0(ret[0]);
+}
 function evalVcadSourceWithModules(source, modules_json) {
   const ptr0 = passStringToWasm0(source, wasm.__wbindgen_malloc, wasm.__wbindgen_realloc);
   const len0 = WASM_VECTOR_LEN;
@@ -8984,6 +8996,38 @@ function costSheetMetalChain(chain, kernel2, rates, quantity2 = 1) {
   }
   return { breakdown: parsed.breakdown, rates: parsed.rates };
 }
+function flattenSolidToSheetMetal(mesh, kernel2, options = {}) {
+  if (!kernel2.flattenSolidToSheetMetal) {
+    throw new Error("kernel.flattenSolidToSheetMetal not available \u2014 rebuild @vcad/kernel-wasm");
+  }
+  const request = {
+    positions: Array.from(mesh.positions),
+    indices: Array.from(mesh.indices),
+    material: options.material,
+    manualK: options.manualK,
+    shopProfile: options.shopProfile,
+    volumeTolFrac: options.volumeTolFrac,
+    planeAngleTolDeg: options.planeAngleTolDeg,
+    planeOffsetTol: options.planeOffsetTol
+  };
+  const parsed = JSON.parse(kernel2.flattenSolidToSheetMetal(JSON.stringify(request)));
+  if (parsed.error) {
+    throw new Error(parsed.error);
+  }
+  return {
+    flatPattern: parsed.flat_pattern,
+    model: parsed.model,
+    dxf: parsed.dxf,
+    violations: parsed.violations,
+    thickness: parsed.thickness,
+    panels: parsed.panels,
+    bends: parsed.bends,
+    solidVolumeMm3: parsed.solid_volume_mm3,
+    recoveredVolumeMm3: parsed.recovered_volume_mm3,
+    volumeErrorFrac: parsed.volume_error_frac,
+    warnings: parsed.warnings ?? []
+  };
+}
 var DEFAULT_SHOP_PROFILE, DEFAULT_COST_RATES, DEFAULT_NESTING_PARAMS;
 var init_sheet_metal = __esm({
   "../engine/dist/sheet-metal.js"() {
@@ -11526,6 +11570,7 @@ var init_dist = __esm({
           WasmAnnotationLayer: wasmModule7.WasmAnnotationLayer,
           projectMesh: wasmModule7.projectMesh,
           importStepBuffer: wasmModule7.importStepBuffer,
+          documentToStepBuffer: wasmModule7.documentToStepBuffer,
           importUrdfBuffer: wasmModule7.importUrdfBuffer,
           exportProjectedViewToDxf: wasmModule7.exportProjectedViewToDxf,
           offsetSectionMesh: wasmModule7.offsetSectionMesh,
@@ -11551,6 +11596,7 @@ var init_dist = __esm({
           getSheetMetalBendTable: wasmModule7.getSheetMetalBendTable,
           getSheetMetalShopCatalog: wasmModule7.getSheetMetalShopCatalog,
           sheetMetalFoldedStep: wasmModule7.sheetMetalFoldedStep,
+          flattenSolidToSheetMetal: wasmModule7.flattenSolidToSheetMetal,
           mesh_clearance: wasmModule7.mesh_clearance,
           topologyOptimizeBox: wasmModule7.topologyOptimizeBox,
           topologyOptimizeMesh: wasmModule7.topologyOptimizeMesh,
@@ -12127,6 +12173,12 @@ var init_dist = __esm({
       nestSheetMetalParts(parts, params) {
         return nestSheetMetalParts2(parts, this.kernel, params);
       }
+      /** Recover a flat pattern (panels, bends, DXF) from a solid part's mesh —
+       *  the mechanical counterpart of `board_from_solid`. Throws when the solid
+       *  is not constant-thickness sheet. */
+      flattenSolidToSheetMetal(mesh, options) {
+        return flattenSolidToSheetMetal(mesh, this.kernel, options);
+      }
       /** Compute a feasible bend sequence (outermost-first) for the
        *  sheet-metal part in `doc`. Returns `null` if there is none. */
       sheetMetalSequence(doc) {
@@ -12202,6 +12254,19 @@ var init_dist = __esm({
           return null;
         return foldedSheetMetalStep(chain, this.kernel);
       }
+      /**
+       * Export the document's scene roots to a STEP AP214 buffer, preserving
+       * BRep through booleans, transforms, fillets, and sweeps — one STEP body
+       * per visible root. Throws when a root evaluated to mesh-only geometry
+       * (the kernel error names the offending roots) or when the loaded WASM
+       * kernel predates the binding.
+       */
+      documentStep(doc) {
+        if (!this.kernel.documentToStepBuffer) {
+          throw new Error("documentToStepBuffer is not available in this kernel build \u2014 rebuild the WASM kernel");
+        }
+        return this.kernel.documentToStepBuffer(JSON.stringify(doc));
+      }
       /** Create a detail view (magnified region) from a projected view.
        *
        * @param view - The parent projected view
@@ -40977,6 +41042,23 @@ var init_CHANGELOG = __esm({
             "verify_receipt"
           ]
         },
+        {
+          id: "2026-07-26-step-export-booleans",
+          version: "0.9.4",
+          date: "2026-07-26",
+          category: "feat",
+          title: "STEP export works on real parts, booleans included",
+          summary: "STEP AP214 export now serializes the evaluated BRep \u2014 booleans, transforms, fillets, and sweeps keep analytic faces \u2014 with one named body per part; mesh-only parts are refused by name.",
+          features: [
+            "step",
+            "export",
+            "booleans",
+            "cnc"
+          ],
+          mcpTools: [
+            "export_cad"
+          ]
+        },
         {
           id: "2026-07-26-render-loon-directly",
           version: "0.9.4",
@@ -40990,6 +41072,20 @@ var init_CHANGELOG = __esm({
             "rendering"
           ]
         },
+        {
+          id: "2026-07-26-photoreal-path-tracer",
+          version: "0.9.4",
+          date: "2026-07-26",
+          category: "feat",
+          title: "Photorealistic rendering with --photoreal",
+          summary: "vcad-render gains a physically-based path tracer: GGX materials with clearcoat, studio softbox lighting, global illumination, and a real camera lens with depth of field.",
+          features: [
+            "rendering",
+            "raytracing",
+            "cli",
+            "materials"
+          ]
+        },
         {
           id: "2026-07-26-parametric-loon-datums",
           version: "0.9.4",
@@ -41048,6 +41144,24 @@ var init_CHANGELOG = __esm({
             "export_cad"
           ]
         },
+        {
+          id: "2026-07-26-flat-pattern-from-solid",
+          version: "0.9.4",
+          date: "2026-07-26",
+          category: "feat",
+          title: "Flat patterns from parts you already modelled",
+          summary: "flat_pattern_from_solid turns any constant-thickness solid into a fab-ready DXF plus a bend table \u2014 no sheet-metal re-authoring \u2014 batching a whole assembly into unique patterns x quantity.",
+          features: [
+            "sheet-metal",
+            "manufacturing",
+            "mcp"
+          ],
+          mcpTools: [
+            "flat_pattern_from_solid",
+            "sheet_metal_nest",
+            "sheet_metal_cost"
+          ]
+        },
         {
           id: "2026-07-26-fastener-forms",
           version: "0.9.4",
@@ -47874,13 +47988,13 @@ function computeIntegrity(doc, engine) {
       cx += v * (p1[0] + p2[0] + p3[0]) / 4;
       cy += v * (p1[1] + p2[1] + p3[1]) / 4;
       cz += v * (p1[2] + p2[2] + p3[2]) / 4;
-      for (const q of [p1, p2, p3]) {
-        bbox.min.x = Math.min(bbox.min.x, q[0]);
-        bbox.min.y = Math.min(bbox.min.y, q[1]);
-        bbox.min.z = Math.min(bbox.min.z, q[2]);
-        bbox.max.x = Math.max(bbox.max.x, q[0]);
-        bbox.max.y = Math.max(bbox.max.y, q[1]);
-        bbox.max.z = Math.max(bbox.max.z, q[2]);
+      for (const q2 of [p1, p2, p3]) {
+        bbox.min.x = Math.min(bbox.min.x, q2[0]);
+        bbox.min.y = Math.min(bbox.min.y, q2[1]);
+        bbox.min.z = Math.min(bbox.min.z, q2[2]);
+        bbox.max.x = Math.max(bbox.max.x, q2[0]);
+        bbox.max.y = Math.max(bbox.max.y, q2[1]);
+        bbox.max.z = Math.max(bbox.max.z, q2[2]);
       }
     }
     const label = labels[partIndex] ?? `part ${partIndex + 1}`;
@@ -50295,8 +50409,8 @@ function buildPartLabels(doc) {
   });
 }
 function eulerXyzDegToQuat2(rotation) {
-  const q = exportKernel().eulerXyzDegToQuat(rotation.x, rotation.y, rotation.z);
-  return [q[0], q[1], q[2], q[3]];
+  const q2 = exportKernel().eulerXyzDegToQuat(rotation.x, rotation.y, rotation.z);
+  return [q2[0], q2[1], q2[2], q2[3]];
 }
 function buildGlb(inputMeshes, name, animation) {
   let f32Len = 0;
@@ -51125,9 +51239,9 @@ var init_store = __esm({
       async listOrders(userId, filter) {
         try {
           const limit = typeof filter.limit === "number" ? filter.limit : 50;
-          let q = `?user_id=eq.${encodeURIComponent(userId)}&order=created_at.desc&limit=${limit}`;
-          if (filter.status) q += `&state=eq.${encodeURIComponent(filter.status)}`;
-          const res = await fabricateFetch(this.url("orders", q), {
+          let q2 = `?user_id=eq.${encodeURIComponent(userId)}&order=created_at.desc&limit=${limit}`;
+          if (filter.status) q2 += `&state=eq.${encodeURIComponent(filter.status)}`;
+          const res = await fabricateFetch(this.url("orders", q2), {
             method: "GET",
             headers: this.headers()
           });
@@ -51331,8 +51445,8 @@ var init_store = __esm({
        *  can retry before deciding what to say. Never throws. */
       async postRow(table, row, onConflict) {
         try {
-          const q = onConflict ? `?on_conflict=${onConflict}` : "";
-          const res = await fabricateFetch(this.url(table, q), {
+          const q2 = onConflict ? `?on_conflict=${onConflict}` : "";
+          const res = await fabricateFetch(this.url(table, q2), {
             method: "POST",
             headers: this.headers({
               Prefer: onConflict ? "resolution=merge-duplicates,return=minimal" : "return=minimal"
@@ -53378,6 +53492,7 @@ var init_tool_metadata = __esm({
       // ── Sheet metal ────────────────────────────────────────────────────────
       sheet_metal_create: { title: "Create Sheet Metal", annotations: RW },
       sheet_metal_unfold: { title: "Unfold Sheet Metal", annotations: RO },
+      flat_pattern_from_solid: { title: "Flat Pattern From Solid", annotations: RO },
       sheet_metal_check: { title: "Check Sheet Metal", annotations: RO },
       sheet_metal_materials: { title: "Sheet Metal Materials", annotations: RO },
       sheet_metal_bend_table: { title: "Sheet Metal Bend Table", annotations: RO },
@@ -54693,34 +54808,34 @@ var init_broker = __esm({
         );
         const built = [];
         for (const adapter of eligible) {
-          let q;
+          let q2;
           try {
-            q = await adapter.quote(req);
+            q2 = await adapter.quote(req);
           } catch {
-            q = null;
+            q2 = null;
           }
-          if (!q) continue;
+          if (!q2) continue;
           const landed2 = estimateLandedCost({
             region: adapter.region,
             supportsDdp: adapter.supportsDdp
           });
-          const markedUp = applyMargin(q.fab_cost_minor);
+          const markedUp = applyMargin(q2.fab_cost_minor);
           const totalMinor = markedUp + landed2.shipping_minor + landed2.duty_minor;
-          const orderable = CONTRACTED_FABS.has(adapter.key) && q.pricing_basis === "binding";
+          const orderable = CONTRACTED_FABS.has(adapter.key) && q2.pricing_basis === "binding";
           built.push({
-            fabCost: q.fab_cost_minor,
+            fabCost: q2.fab_cost_minor,
             option: {
               fab: adapter.key,
               fab_label: adapter.label,
               region: adapter.region,
               unit_price_minor: Math.round(totalMinor / req.quantity),
               total_minor: totalMinor,
-              lead_time_days: q.lead_time_days,
-              in_spec: q.in_spec,
-              pricing_basis: q.pricing_basis,
+              lead_time_days: q2.lead_time_days,
+              in_spec: q2.in_spec,
+              pricing_basis: q2.pricing_basis,
               supports_ddp: adapter.supportsDdp,
               orderable,
-              notes: q.notes
+              notes: q2.notes
             }
           });
         }
@@ -55910,7 +56025,7 @@ function measureGroups(engine, candidates, groupA, groupB) {
       error: `No part with id or name ${missing.map((m) => `"${m}"`).join(", ")}. Available: ${available || "none"}`
     };
   }
-  const overlap = a.parts.filter((p) => b.parts.some((q) => q.id === p.id));
+  const overlap = a.parts.filter((p) => b.parts.some((q2) => q2.id === p.id));
   if (overlap.length > 0) {
     return {
       error: `Parts cannot appear in both groups: ${overlap.map((p) => p.id).join(", ")}`
@@ -57979,17 +58094,19 @@ function exportCad(input, engine) {
   const filename = String(args.filename ?? "");
   const stepExt = filename.toLowerCase().split(".").pop();
   if (stepExt === "step" || stepExt === "stp") {
-    const step = engine.foldedSheetMetalStep(ir);
-    if (step === null) {
-      throw new Error(
-        "STEP export is only available for sheet-metal documents (the folded body needs B-rep bend geometry). Use .stl or .glb for mesh exports."
-      );
+    const foldedStep = engine.foldedSheetMetalStep(ir);
+    if (foldedStep !== null) {
+      const bytes3 = new TextEncoder().encode(foldedStep);
+      return deliver(filename, bytes3, {
+        format: stepExt,
+        parts: 1,
+        note: "Folded sheet-metal body (AP214) with cylindrical bend faces \u2014 bends/angles/directions auto-detect in 3D fab pipelines."
+      });
     }
-    const bytes2 = new TextEncoder().encode(step);
+    const bytes2 = engine.documentStep(ir);
     return deliver(filename, bytes2, {
       format: stepExt,
-      parts: 1,
-      note: "Folded sheet-metal body (AP214) with cylindrical bend faces \u2014 bends/angles/directions auto-detect in 3D fab pipelines."
+      note: "BRep AP214 export \u2014 analytic faces (planes/cylinders/spheres/cones/tori/NURBS) preserved through booleans; ready for CNC quoting."
     });
   }
   const scene = engine.evaluate(ir);
@@ -58021,7 +58138,7 @@ function exportCad(input, engine) {
       bytes = toGlbBytes(scene, filename);
       break;
     default:
-      throw new Error(`Unsupported format: .${ext}. Use .stl, .glb, or .step (sheet-metal only)`);
+      throw new Error(`Unsupported format: .${ext}. Use .stl, .glb, or .step`);
   }
   return deliver(filename, bytes, {
     format: ext,
@@ -58060,7 +58177,7 @@ var init_export = __esm({
         },
         filename: {
           type: "string",
-          description: "Output filename with extension (.stl, .glb, or \u2014 for sheet-metal documents \u2014 .step/.stp), relative to the server working directory (or VCAD_MCP_EXPORT_DIR if set). STEP exports the FOLDED sheet-metal body (AP214) with true cylindrical bend faces sized by the document's shop profile, so fab services with a 3D pipeline (e.g. SendCutSend) auto-detect bends, angles, and directions with zero data entry."
+          description: "Output filename with extension (.stl, .glb, or .step/.stp), relative to the server working directory (or VCAD_MCP_EXPORT_DIR if set). STEP is a BRep AP214 export: booleans, transforms, fillets, and sweeps keep true analytic faces (the format CNC vendors quote from). Sheet-metal documents export the FOLDED body with cylindrical bend faces auto-detected by 3D fab pipelines (e.g. SendCutSend). Parts built from imported meshes have no BRep and are refused by name \u2014 export those as STL."
         },
         joint_state: jointStateSchemaProp
       },
@@ -58070,7 +58187,7 @@ var init_export = __esm({
       {
         name: "export_cad",
         pack: null,
-        description: "Export a CAD document to a file. Supports STL (3D printing), GLB (visualization), and \u2014 for sheet-metal documents \u2014 STEP AP214 of the FOLDED body with true cylindrical bend faces (fab 3D pipelines like SendCutSend auto-detect bends/angles/directions; zero data entry). Format is determined by file extension. Pass `joint_state` to export a jointed assembly at a real pose (joint id or name \u2192 degrees, or mm for sliders) instead of its zero pose.",
+        description: "Export a CAD document to a file. Supports STL (3D printing), GLB (visualization), and STEP AP214 (CNC quoting: BRep with true analytic faces, preserved through booleans/transforms/fillets/sweeps; sheet-metal documents export the FOLDED body with cylindrical bend faces that 3D fab pipelines like SendCutSend auto-detect). Mesh-only parts (imported meshes) can't go to STEP and are refused by name \u2014 use STL for those. Format is determined by file extension. Pass `joint_state` to export a jointed assembly at a real pose (joint id or name \u2192 degrees, or mm for sliders) instead of its zero pose.",
         inputSchema: exportCadSchema,
         handler: (a, c) => exportCad(a, c.engine),
         behavior: behavior({})
@@ -60068,10 +60185,10 @@ function detectStaleNets(pcb) {
     const onSegBody = (p, t2) => segDist(p, t2) <= t2.width / 2 + 0.02;
     const anchored = (p, selfIdx, halfW) => {
       if (pads.some(
-        (q) => Math.hypot(p.x - q.pos.x, p.y - q.pos.y) <= q.halfExtent + halfW + 0.02
+        (q2) => Math.hypot(p.x - q2.pos.x, p.y - q2.pos.y) <= q2.halfExtent + halfW + 0.02
       ))
         return true;
-      if (vias.some((q) => Math.hypot(p.x - q.x, p.y - q.y) <= halfW + 0.42)) return true;
+      if (vias.some((q2) => Math.hypot(p.x - q2.x, p.y - q2.y) <= halfW + 0.42)) return true;
       for (let j = 0; j < traces.length; j++) {
         if (j === selfIdx) continue;
         if (segDist(p, traces[j]) <= traces[j].width / 2 + halfW + 0.02) return true;
@@ -61871,7 +61988,7 @@ function seedScan(residual, lo, hi, perDim = 12) {
   const idx = new Array(n).fill(0);
   const total = Math.pow(perDim, n);
   for (let c = 0; c < total; c++) {
-    const x = idx.map((q, d) => lo[d] + (hi[d] - lo[d]) * q / (perDim - 1));
+    const x = idx.map((q2, d) => lo[d] + (hi[d] - lo[d]) * q2 / (perDim - 1));
     const cost = sumSq(residual(x));
     if (cost < best.cost) {
       best.cost = cost;
@@ -62412,7 +62529,7 @@ function calcRf(args) {
     return fail2("topology must be 'series_rlc' or 'parallel_rlc'");
   }
   const f0 = 1 / (2 * Math.PI * Math.sqrt(l * c));
-  const q = topology === "series_rlc" ? r > 0 ? 1 / r * Math.sqrt(l / c) : Infinity : r * Math.sqrt(c / l);
+  const q2 = topology === "series_rlc" ? r > 0 ? 1 / r * Math.sqrt(l / c) : Infinity : r * Math.sqrt(c / l);
   const fStart = args.f_start_hz ?? f0 * 0.1;
   const fStop = args.f_stop_hz ?? f0 * 10;
   const points = Math.min(256, Math.max(3, Math.round(args.points ?? 21)));
@@ -62458,7 +62575,7 @@ function calcRf(args) {
           success: true,
           topology,
           resonance_hz: Math.round(f0),
-          q_factor: Number.isFinite(q) ? r3(q) : 999999,
+          q_factor: Number.isFinite(q2) ? r3(q2) : 999999,
           z_at_resonance_ohm: r3(mag(z0re, z0im)),
           best_match: {
             f_hz: best.f_hz,
@@ -62473,8 +62590,8 @@ function calcRf(args) {
               l_henry: l,
               c_farad: c
             }),
-            ...Number.isFinite(q) ? [
-              emClaim("q_factor", r3(q), "dimensionless", "rlc-analytic", {
+            ...Number.isFinite(q2) ? [
+              emClaim("q_factor", r3(q2), "dimensionless", "rlc-analytic", {
                 topology,
                 r_ohm: r,
                 l_henry: l,
@@ -63053,17 +63170,17 @@ async function setBoardOutline(args) {
   };
 }
 function scoreFootprintFamily(query, fam) {
-  const q = query.toLowerCase().trim();
-  if (!q) return 0;
+  const q2 = query.toLowerCase().trim();
+  if (!q2) return 0;
   const cands = [fam.family, fam.label, ...fam.aliases].map((s) => s.toLowerCase());
   let best = 0;
   for (const c of cands) {
-    if (c === q) {
+    if (c === q2) {
       best = Math.max(best, 1);
-    } else if (c.includes(q) || q.includes(c)) {
+    } else if (c.includes(q2) || q2.includes(c)) {
       best = Math.max(best, 0.75);
     } else {
-      const sim = 1 - editDistance(q, c) / Math.max(q.length, c.length);
+      const sim = 1 - editDistance(q2, c) / Math.max(q2.length, c.length);
       best = Math.max(best, sim * 0.6);
     }
   }
@@ -64696,16 +64813,16 @@ function windSegClosestPt(a, b, c, d) {
   };
   let best = [a, clamp(a, c, d)];
   let bestD = Infinity;
-  for (const [p, q] of [
+  for (const [p, q2] of [
     [a, clamp(a, c, d)],
     [b, clamp(b, c, d)],
     [c, clamp(c, a, b)],
     [d, clamp(d, a, b)]
   ]) {
-    const dd = Math.hypot(p.x - q.x, p.y - q.y);
+    const dd = Math.hypot(p.x - q2.x, p.y - q2.y);
     if (dd < bestD) {
       bestD = dd;
-      best = [p, q];
+      best = [p, q2];
     }
   }
   return { x: (best[0].x + best[1].x) / 2, y: (best[0].y + best[1].y) / 2 };
@@ -65323,7 +65440,7 @@ function calcMotorInduction(args, polePairs, turnsPerPhase, windingFactor, inner
     outer_radius_mm: outerR,
     end_effect_factor: endEffect
   };
-  const claim2 = (q, v, unit) => emClaim(q, sig6(v), unit, "thin-sheet-induction", inductionInputs);
+  const claim2 = (q2, v, unit) => emClaim(q2, sig6(v), unit, "thin-sheet-induction", inductionInputs);
   return {
     content: [
       {
@@ -65751,11 +65868,11 @@ function polygonCentroid(poly) {
   let cy = 0;
   for (let i = 0; i < poly.length; i++) {
     const p = poly[i];
-    const q = poly[(i + 1) % poly.length];
-    const cross = p.x * q.y - q.x * p.y;
+    const q2 = poly[(i + 1) % poly.length];
+    const cross = p.x * q2.y - q2.x * p.y;
     a += cross;
-    cx += (p.x + q.x) * cross;
-    cy += (p.y + q.y) * cross;
+    cx += (p.x + q2.x) * cross;
+    cy += (p.y + q2.y) * cross;
   }
   if (Math.abs(a) < 1e-12) {
     const n = poly.length || 1;
@@ -74151,8 +74268,8 @@ function normaliseEngravings(raw) {
         if (Array.isArray(p) && p.length >= 2)
           return { x: Number(p[0]), y: Number(p[1]) };
         if (p && typeof p === "object" && "x" in p && "y" in p) {
-          const q = p;
-          return { x: Number(q.x), y: Number(q.y) };
+          const q2 = p;
+          return { x: Number(q2.x), y: Number(q2.y) };
         }
         return null;
       }).filter((p) => p !== null) : [];
@@ -74817,6 +74934,222 @@ var init_sheet_metal2 = __esm({
   }
 });
 
+// src/tools/flat-pattern.ts
+function q(v, dp = 3) {
+  const f = 10 ** dp;
+  const r = Math.round(v * f) / f;
+  return r === 0 ? 0 : r;
+}
+function ringSignature(ring) {
+  const n = ring.length;
+  if (n < 3) return "";
+  const terms = [];
+  for (let i = 0; i < n; i++) {
+    const a = ring[(i + n - 1) % n];
+    const b = ring[i];
+    const c = ring[(i + 1) % n];
+    const e1 = [b[0] - a[0], b[1] - a[1]];
+    const e2 = [c[0] - b[0], c[1] - b[1]];
+    const len = Math.hypot(e2[0], e2[1]);
+    const turn = Math.atan2(
+      e1[0] * e2[1] - e1[1] * e2[0],
+      e1[0] * e2[0] + e1[1] * e2[1]
+    );
+    terms.push(`${q(len, 2)}:${q(turn, 3)}`);
+  }
+  let best = null;
+  for (let r = 0; r < n; r++) {
+    const cand = terms.slice(r).concat(terms.slice(0, r)).join(",");
+    if (best === null || cand < best) best = cand;
+  }
+  return best ?? "";
+}
+function patternSignature(r) {
+  const sil = r.flatPattern.silhouette_2d ?? [];
+  const outer = ringSignature(sil[0] ?? []);
+  const holes = sil.slice(1).map((h) => ringSignature(h)).sort().join("|");
+  const bends = r.bends.map((b) => `${q(b.angle_deg, 2)}/${q(b.radius, 3)}/${q(b.length, 2)}/${b.direction}`).sort().join("|");
+  return `t${q(r.thickness)}|${outer}|H:${holes}|B:${bends}`;
+}
+function solidParts(doc, engine) {
+  const scene = engine.evaluate(doc);
+  const visibleRoots = doc.roots.filter((e) => e.visible !== false);
+  const out = [];
+  for (let i = 0; i < scene.parts.length && i < visibleRoots.length; i++) {
+    const rootId = visibleRoots[i].root;
+    const node = doc.nodes[String(rootId)];
+    const mesh = scene.parts[i].mesh;
+    if (!mesh || mesh.positions.length === 0) continue;
+    out.push({ rootId, name: node?.name ?? void 0, mesh });
+  }
+  return out;
+}
+function flatPatternFromSolid(input, engine) {
+  const a = input ?? {};
+  const doc = getSession(String(a.document_id ?? ""));
+  const includeDxf = a.include_dxf !== false;
+  const options = {
+    material: typeof a.material === "string" ? a.material : void 0,
+    manualK: typeof a.manual_k === "number" ? a.manual_k : void 0,
+    shopProfile: typeof a.shop_profile === "string" ? a.shop_profile : void 0,
+    volumeTolFrac: typeof a.volume_tolerance === "number" ? a.volume_tolerance : void 0
+  };
+  const all = solidParts(doc, engine);
+  if (all.length === 0) {
+    throw new Error("Document has no solid parts to flatten");
+  }
+  const partId = a.part_id !== void 0 ? String(a.part_id) : void 0;
+  const targets = partId ? all.filter((p) => String(p.rootId) === partId) : all;
+  if (targets.length === 0) {
+    throw new Error(
+      `No part with id "${partId}". Available: ${all.map((c) => `${c.rootId}${c.name ? ` (${c.name})` : ""}`).join(", ")}`
+    );
+  }
+  const groups = /* @__PURE__ */ new Map();
+  const failed = [];
+  for (const part of targets) {
+    let r;
+    try {
+      r = engine.flattenSolidToSheetMetal(part.mesh, options);
+    } catch (e) {
+      failed.push({
+        root_id: part.rootId,
+        ...part.name ? { name: part.name } : {},
+        reason: e instanceof Error ? e.message : String(e)
+      });
+      continue;
+    }
+    const sig = patternSignature(r);
+    const existing = groups.get(sig);
+    if (existing) {
+      existing.quantity += 1;
+      existing.parts.push({
+        root_id: part.rootId,
+        ...part.name ? { name: part.name } : {}
+      });
+      continue;
+    }
+    const [minX, minY, maxX, maxY] = r.flatPattern.bbox;
+    const creases = r.flatPattern.creases ?? [];
+    groups.set(sig, {
+      pattern_id: `pattern-${groups.size + 1}`,
+      quantity: 1,
+      parts: [{ root_id: part.rootId, ...part.name ? { name: part.name } : {} }],
+      thickness_mm: r.thickness,
+      flat: {
+        bbox: r.flatPattern.bbox,
+        area_mm2: r.flatPattern.area_mm2,
+        width_mm: Math.abs(maxX - minX),
+        height_mm: Math.abs(maxY - minY)
+      },
+      panels: r.panels,
+      bend_table: r.bends.map((b, i) => ({
+        bend: b.bend,
+        angle_deg: b.angle_deg,
+        radius_mm: b.radius,
+        length_mm: b.length,
+        direction: b.direction,
+        k_factor: b.k_factor,
+        allowance_mm: b.angle_deg * Math.PI / 180 * (b.radius + b.k_factor * r.thickness),
+        line: creases[i] ? creases[i].line : []
+      })),
+      verification: {
+        solid_volume_mm3: r.solidVolumeMm3,
+        recovered_volume_mm3: r.recoveredVolumeMm3,
+        error_frac: r.volumeErrorFrac,
+        status: "verified"
+      },
+      violations: r.violations,
+      warnings: r.warnings,
+      ...includeDxf ? { dxf: r.dxf } : {}
+    });
+  }
+  const patterns = [...groups.values()];
+  if (patterns.length === 0) {
+    throw new Error(
+      `No part in this document is constant-thickness sheet. ${failed.map((f) => `${f.name ?? f.root_id}: ${f.reason}`).join("; ")}`
+    );
+  }
+  const totalParts = patterns.reduce((s, p) => s + p.quantity, 0);
+  const bends = patterns.reduce((s, p) => s + p.bend_table.length * p.quantity, 0);
+  return {
+    content: [
+      {
+        type: "text",
+        text: JSON.stringify(
+          {
+            success: true,
+            patterns,
+            ...failed.length > 0 ? { not_sheet_metal: failed } : {},
+            nest_input: patterns.map((p) => ({
+              name: p.pattern_id,
+              width_mm: p.flat.width_mm,
+              height_mm: p.flat.height_mm,
+              quantity: p.quantity
+            })),
+            summary: `${patterns.length} unique pattern(s) covering ${totalParts} part(s), ${bends} bend(s) total${failed.length > 0 ? `; ${failed.length} part(s) are not sheet metal` : ""}. Every pattern is volume-verified against its solid.`,
+            note: "Each DXF is a fab-ready merged silhouette in millimetres: one closed exterior polyline + hole loops on CUT, DASHED bend centerlines on BEND_UP/BEND_DOWN. DXF carries no bend angles \u2014 use `bend_table` (angle, inside radius, direction, allowance, crease line) when entering them in the fab's UI. Hand `nest_input` to sheet_metal_nest, then sheet_metal_cost, for a quote."
+          },
+          null,
+          2
+        )
+      }
+    ]
+  };
+}
+var flatPatternFromSolidSchema, toolDefs41;
+var init_flat_pattern = __esm({
+  "src/tools/flat-pattern.ts"() {
+    "use strict";
+    init_session2();
+    init_tool_def();
+    flatPatternFromSolidSchema = {
+      type: "object",
+      properties: {
+        document_id: {
+          type: "string",
+          description: "CAD session id (open_document / create_cad_loon) holding the solid(s)."
+        },
+        part_id: {
+          type: "string",
+          description: "Root id of a single part to flatten (from `read`). Omit to flatten every solid part in the document and group identical parts into one pattern \xD7 quantity."
+        },
+        material: {
+          type: "string",
+          description: 'Material key for K-factor lookup (e.g. "al-soft", "steel-mild"). Default "al-soft". See sheet_metal_materials.'
+        },
+        manual_k: {
+          type: "number",
+          description: "Override the K-factor for every recovered bend (skips the bend table)."
+        },
+        shop_profile: {
+          type: "string",
+          description: 'Fab-service catalog id (e.g. "sendcutsend") to run manufacturability against. Default: generic shop.'
+        },
+        volume_tolerance: {
+          type: "number",
+          description: "Max relative volume error the round-trip check accepts (default 0.02). Re-extruding the emitted profile by the detected thickness must reproduce the solid's volume; a mismatch fails the part."
+        },
+        include_dxf: {
+          type: "boolean",
+          description: "Include the DXF string per pattern. Default true."
+        }
+      },
+      required: ["document_id"]
+    };
+    toolDefs41 = [
+      {
+        name: "flat_pattern_from_solid",
+        pack: "sheet_metal",
+        description: "Emit the flat pattern (DXF + bend table) for a part that was modelled as an ordinary solid \u2014 extruded sketch, boolean, imported STEP \u2014 with no sheet-metal authoring required. The mechanical counterpart of board_from_solid: it detects the constant-thickness walls and the cylindrical bends between them, returns the cut profile (outer boundary + every interior hole) with the detected thickness, and a bend table (line positions, angles, direction, allowance) for bent parts. Called without part_id it batches the whole document and groups identical parts into one pattern \xD7 quantity (mirror images stay separate). Fails closed: re-extruding the emitted profile by the detected thickness must reproduce the solid's volume, so a part that isn't really constant-thickness sheet is reported as such instead of yielding a wrong outline.",
+        inputSchema: flatPatternFromSolidSchema,
+        handler: (a, c) => flatPatternFromSolid(a, c.engine),
+        behavior: behavior({ geometry: true })
+      }
+    ];
+  }
+});
+
 // src/tools/acoustics.ts
 import { writeFileSync as writeFileSync5 } from "node:fs";
 function lookupMaterial(engine, name) {
@@ -74985,7 +75318,7 @@ function simulateStrike(input, engine) {
   }
   return { content: [{ type: "text", text: JSON.stringify(payload, null, 2) }] };
 }
-var cents, MATERIAL_ALIASES, simulateStrikeSchema, round23, round4, toolDefs41;
+var cents, MATERIAL_ALIASES, simulateStrikeSchema, round23, round4, toolDefs42;
 var init_acoustics = __esm({
   "src/tools/acoustics.ts"() {
     "use strict";
@@ -75059,7 +75392,7 @@ var init_acoustics = __esm({
     };
     round23 = (x) => Math.round(x * 100) / 100;
     round4 = (x) => Math.round(x * 1e4) / 1e4;
-    toolDefs41 = [
+    toolDefs42 = [
       {
         name: "simulate_strike",
         pack: "sheet_metal",
@@ -75210,7 +75543,7 @@ function importStep(input, engine) {
     ]
   };
 }
-var MAX_STEP_BYTES, importStepSchema, toolDefs42;
+var MAX_STEP_BYTES, importStepSchema, toolDefs43;
 var init_import = __esm({
   "src/tools/import.ts"() {
     "use strict";
@@ -75242,7 +75575,7 @@ var init_import = __esm({
         }
       }
     };
-    toolDefs42 = [
+    toolDefs43 = [
       {
         name: "import_step",
         pack: null,
@@ -75370,7 +75703,7 @@ function importEagle(_input) {
     "Eagle (.brd) import is not yet supported. Export your board from Eagle as KiCad (File > Export > KiCad .kicad_pcb) and use import_kicad instead."
   );
 }
-var MAX_PCB_BYTES, importKicadSchema, importEagleSchema, toolDefs43;
+var MAX_PCB_BYTES, importKicadSchema, importEagleSchema, toolDefs44;
 var init_import_pcb = __esm({
   "src/tools/import-pcb.ts"() {
     "use strict";
@@ -75411,7 +75744,7 @@ var init_import_pcb = __esm({
         }
       }
     };
-    toolDefs43 = [
+    toolDefs44 = [
       {
         name: "import_kicad",
         pack: "ecad",
@@ -75507,7 +75840,7 @@ Compressed URL param: ${encoded.length} bytes`
     ]
   };
 }
-var openInBrowserSchema, toolDefs44;
+var openInBrowserSchema, toolDefs45;
 var init_share = __esm({
   "src/tools/share.ts"() {
     "use strict";
@@ -75531,7 +75864,7 @@ var init_share = __esm({
         }
       }
     };
-    toolDefs44 = [
+    toolDefs45 = [
       {
         name: "open_in_browser",
         pack: null,
@@ -75964,7 +76297,7 @@ function batchReset(input) {
     };
   }
 }
-var simulations, MAX_TRAJECTORY, envRecords, batchGroups, INLINE_DOC_DESC, SESSION_DOC_DESC, createRobotEnvSchema, gymStepSchema, gymResetSchema, gymObserveSchema, gymCloseSchema, batchCreateEnvsSchema, batchStepSchema, batchResetSchema, toolDefs45;
+var simulations, MAX_TRAJECTORY, envRecords, batchGroups, INLINE_DOC_DESC, SESSION_DOC_DESC, createRobotEnvSchema, gymStepSchema, gymResetSchema, gymObserveSchema, gymCloseSchema, batchCreateEnvsSchema, batchStepSchema, batchResetSchema, toolDefs46;
 var init_gym = __esm({
   "src/tools/gym.ts"() {
     "use strict";
@@ -76126,7 +76459,7 @@ var init_gym = __esm({
       },
       required: ["batch_id"]
     };
-    toolDefs45 = [
+    toolDefs46 = [
       {
         name: "create_robot_env",
         pack: "physics",
@@ -76484,7 +76817,7 @@ async function renderMolecule(input) {
     return fail(err7);
   }
 }
-var loadStructureSchema, inspectMoleculeSchema, configSchema, minimizeEnergySchema, mdRunSchema, designMaterialSchema, homogenizeMaterialSchema, renderMoleculeSchema, CPK, DEFAULT_RADIUS, toolDefs46;
+var loadStructureSchema, inspectMoleculeSchema, configSchema, minimizeEnergySchema, mdRunSchema, designMaterialSchema, homogenizeMaterialSchema, renderMoleculeSchema, CPK, DEFAULT_RADIUS, toolDefs47;
 var init_atoms2 = __esm({
   "src/tools/atoms.ts"() {
     "use strict";
@@ -76619,7 +76952,7 @@ var init_atoms2 = __esm({
       S: 1.05,
       P: 1.07
     };
-    toolDefs46 = [
+    toolDefs47 = [
       {
         name: "load_structure",
         pack: "atoms",
@@ -77827,7 +78160,7 @@ function errorResult(text) {
     isError: true
   };
 }
-var recordSimulationSchema, SVG_SCALE2, MAX_STEPS, MIN_STEPS, DEFAULT_WIDTH_PX2, MIN_WIDTH_PX, MAX_WIDTH_PX, DEFAULT_FPS, MIN_FPS, MAX_FPS, toolDefs47;
+var recordSimulationSchema, SVG_SCALE2, MAX_STEPS, MIN_STEPS, DEFAULT_WIDTH_PX2, MIN_WIDTH_PX, MAX_WIDTH_PX, DEFAULT_FPS, MIN_FPS, MAX_FPS, toolDefs48;
 var init_record2 = __esm({
   "src/tools/record.ts"() {
     "use strict";
@@ -77891,7 +78224,7 @@ var init_record2 = __esm({
     DEFAULT_FPS = 30;
     MIN_FPS = 1;
     MAX_FPS = 60;
-    toolDefs47 = [
+    toolDefs48 = [
       {
         name: "record_simulation",
         pack: "physics",
@@ -77984,7 +78317,7 @@ ${text}`
     ]
   };
 }
-var getChangelogSchema, toolDefs48;
+var getChangelogSchema, toolDefs49;
 var init_changelog2 = __esm({
   "src/tools/changelog.ts"() {
     "use strict";
@@ -78024,7 +78357,7 @@ var init_changelog2 = __esm({
         }
       }
     };
-    toolDefs48 = [
+    toolDefs49 = [
       {
         name: "get_changelog",
         pack: null,
@@ -78173,7 +78506,7 @@ function getSimVersion(input) {
     ]
   };
 }
-var getSimReplaySchema, getSimVersionSchema, toolDefs49;
+var getSimReplaySchema, getSimVersionSchema, toolDefs50;
 var init_sim_replay = __esm({
   "src/tools/sim-replay.ts"() {
     "use strict";
@@ -78201,7 +78534,7 @@ var init_sim_replay = __esm({
       },
       required: ["env_id"]
     };
-    toolDefs49 = [
+    toolDefs50 = [
       {
         name: "get_sim_replay",
         pack: null,
@@ -78320,7 +78653,7 @@ async function getOrderFeed(input, store, user) {
     version: version2
   });
 }
-var toUsd4, getOrderFeedSchema, toolDefs50;
+var toUsd4, getOrderFeedSchema, toolDefs51;
 var init_order_feed = __esm({
   "src/tools/order-feed.ts"() {
     "use strict";
@@ -78339,7 +78672,7 @@ var init_order_feed = __esm({
       },
       required: ["document_id"]
     };
-    toolDefs50 = [
+    toolDefs51 = [
       {
         name: "get_order_feed",
         pack: "fabricate",
@@ -79241,7 +79574,7 @@ ${issues.map((i) => i.problem).join("\n")}`
     note: "Rollout compiled to the document timeline. Preview with render_sequence, ship with export_video."
   });
 }
-var MAX_FRAMES, MAX_GEO_SAMPLES, MAX_VERIFY_FRAMES, INLINE_GLB_MAX_BASE64, DEFAULT_WIDTH_PX3, MIN_WIDTH_PX2, MAX_WIDTH_PX2, SVG_SCALE3, KEYFRAMES_DESCRIPTION, animateSchema, renderSequenceSchema, CAMERA_NODE, exportVideoSchema, ffmpegAvailable, timelineFromSimulationSchema, toolDefs51;
+var MAX_FRAMES, MAX_GEO_SAMPLES, MAX_VERIFY_FRAMES, INLINE_GLB_MAX_BASE64, DEFAULT_WIDTH_PX3, MIN_WIDTH_PX2, MAX_WIDTH_PX2, SVG_SCALE3, KEYFRAMES_DESCRIPTION, animateSchema, renderSequenceSchema, CAMERA_NODE, exportVideoSchema, ffmpegAvailable, timelineFromSimulationSchema, toolDefs52;
 var init_animate = __esm({
   "src/tools/animate.ts"() {
     "use strict";
@@ -79393,7 +79726,7 @@ var init_animate = __esm({
       },
       required: ["env_id", "document_id"]
     };
-    toolDefs51 = [
+    toolDefs52 = [
       {
         name: "animate",
         pack: null,
@@ -79455,6 +79788,7 @@ function buildInstructions(kernelPrompt) {
     "- See your work with `render_view` (isometric PNG); measure with `inspect_cad` (whole-document volume, area, bbox, center of mass), `inspect_part` / `describe_scene` (per-part bbox, size, center, material), and `measure` (min distance/overlap between two parts, or one part's bbox+volume+center of mass).",
     "- Ship with `export_cad` (STL/GLB/STEP) or `open_in_browser` (vcad.io deep link).",
     "- Fix in place: when geometry is wrong, prefer `update` on the offending node over deleting parts and starting over.",
+    "- Cut sheet parts you already modelled: `flat_pattern_from_solid` turns any constant-thickness solid \u2014 extruded sketch, boolean, imported STEP \u2014 into a fab-ready DXF plus a bend table, no sheet-metal re-authoring. Called without `part_id` it does the whole document and groups identical parts into one pattern \xD7 quantity; hand its `nest_input` to `sheet_metal_nest`, then `sheet_metal_cost`, for a quote. It fails closed: the emitted profile re-extruded by the detected thickness must reproduce the solid's volume.",
     "- Deliver the project bill of materials with `bom_create` \u2192 `bom_export` (markdown/CSV/JSON with landed-cost totals): link quote_manufacturing quotes on manufactured lines, and source COTS hardware (bearings, shafts, standoffs, screws, ferrite magnets) with `search_mechanical_parts`. All BOM prices are estimates and flagged as such.",
     "",
     "",
@@ -80071,6 +80405,7 @@ async function createServer(existingEngine, context = { user: null }) {
 function slimPreviewForInlineUi(result, docId, toolName, clientHasInlineUi) {
   if (!clientHasInlineUi) return;
   if (toolName === "sheet_metal_unfold") return;
+  if (toolName === "flat_pattern_from_solid") return;
   if (PURE_JSON_RESULT_TOOLS.has(toolName)) return;
   const alwaysSlim = toolName === "create_cad_loon";
   const totalChars = result.content.reduce(
@@ -80309,6 +80644,7 @@ var init_server3 = __esm({
     init_loon_macros();
     init_dfm2();
     init_sheet_metal2();
+    init_flat_pattern();
     init_acoustics();
     init_import();
     init_import_pcb();
@@ -80323,8 +80659,8 @@ var init_server3 = __esm({
     init_order_feed();
     init_animate();
     PKG_VERSION = (() => {
-      if ("0.9.4-main.39") {
-        return "0.9.4-main.39";
+      if ("0.9.4-main.41") {
+        return "0.9.4-main.41";
       }
       try {
         const req = createRequire2(import.meta.url);
@@ -80333,8 +80669,8 @@ var init_server3 = __esm({
         return "0.0.0";
       }
     })();
-    BUILD_SHA = "08cd95d4487b522463d0a1a3b58b84935a1f7d08";
-    BUILD_TIME = "2026-07-26T13:56:33.334Z";
+    BUILD_SHA = "b00f071e4b839c6448769107ed84182597d763ed";
+    BUILD_TIME = "2026-07-26T14:41:39.682Z";
     SHORT_SHA = BUILD_SHA === "unknown" ? "unknown" : BUILD_SHA.slice(0, 7);
     VERSION_WITH_BUILD = SHORT_SHA === "unknown" ? PKG_VERSION : `${PKG_VERSION}+${SHORT_SHA}`;
     INSTANCE_ID = randomUUID6().slice(0, 8);
@@ -80407,11 +80743,12 @@ var init_server3 = __esm({
       ...toolDefs46,
       ...toolDefs47,
       ...toolDefs48,
+      ...toolDefs49,
       ...toolDefs20,
       ...toolDefs19,
-      ...toolDefs49,
       ...toolDefs50,
-      ...toolDefs51
+      ...toolDefs51,
+      ...toolDefs52
     ];
     LIST_TOOL_ORDER = [
       // ── Session lifecycle ──────────────────────────────────────
@@ -80518,6 +80855,7 @@ var init_server3 = __esm({
       "sheet_metal_suggest_fix",
       "sheet_metal_sequence",
       "sheet_metal_nest",
+      "flat_pattern_from_solid",
       "simulate_strike",
       // ── Import + share ─────────────────────────────────────────
       "import_step",

package/package.json

@@ -1,6 +1,6 @@
 {
   "name": "@vcad/mcp",
-  "version": "0.9.4-main.39",
+  "version": "0.9.4-main.41",
   "description": "vcad MCP server — parametric CAD + PCB design tools for AI agents (self-contained: bundled server + kernel WASM)",
   "license": "MIT",
   "type": "module",
@@ -19,7 +19,7 @@
   },
   "homepage": "https://vcad.io",
   "vcadBuild": {
-    "sha": "08cd95d4487b522463d0a1a3b58b84935a1f7d08",
-    "builtAt": "2026-07-26T13:56:33.334Z"
+    "sha": "b00f071e4b839c6448769107ed84182597d763ed",
+    "builtAt": "2026-07-26T14:41:39.682Z"
   }
 }