brep-io-kernel 1.0.0-ci.10

package/src/exporters/sheetMetalFlatPattern.js

@@ -0,0 +1,659 @@
+import * as THREE from 'three';
+import { unfoldSheetMetal, exportFlatPatternToSVG } from './sheetMetalUnfold.js';
+import { SHEET_METAL_FACE_TYPES } from '../features/sheetMetal/sheetMetalFaceTypes.js';
+
+const EPS = 1e-12;
+const BEND_SURFACE_TYPES = new Set(['cylindrical', 'conical']);
+
+const makeEdgeKey = (a, b) => (a < b ? `${a}|${b}` : `${b}|${a}`);
+
+function readVec3(value) {
+  if (!Array.isArray(value) || value.length < 3) return null;
+  const x = Number(value[0]);
+  const y = Number(value[1]);
+  const z = Number(value[2]);
+  if (!Number.isFinite(x) || !Number.isFinite(y) || !Number.isFinite(z)) return null;
+  return new THREE.Vector3(x, y, z);
+}
+
+function polylineLength(positions) {
+  if (!Array.isArray(positions) || positions.length < 2) return 0;
+  let length = 0;
+  for (let i = 1; i < positions.length; i++) {
+    const a = positions[i - 1];
+    const b = positions[i];
+    if (!Array.isArray(a) || !Array.isArray(b)) continue;
+    const dx = b[0] - a[0];
+    const dy = b[1] - a[1];
+    const dz = b[2] - a[2];
+    length += Math.hypot(dx, dy, dz);
+  }
+  return length;
+}
+
+function deriveAxisFromBoundary(boundary) {
+  const positions = boundary?.positions;
+  if (!Array.isArray(positions) || positions.length < 2) return null;
+  const a = positions[0];
+  const b = positions[positions.length - 1];
+  if (!Array.isArray(a) || !Array.isArray(b)) return null;
+  const dir = new THREE.Vector3(b[0] - a[0], b[1] - a[1], b[2] - a[2]);
+  if (dir.lengthSq() < EPS) return null;
+  return dir.normalize();
+}
+
+function derivePointFromBoundary(boundary) {
+  const positions = boundary?.positions;
+  if (!Array.isArray(positions) || positions.length === 0) return null;
+  const a = positions[0];
+  if (!Array.isArray(a) || a.length < 3) return null;
+  return new THREE.Vector3(a[0], a[1], a[2]);
+}
+
+function signedAngleAroundAxis(from, to, axis) {
+  const cross = new THREE.Vector3().crossVectors(from, to);
+  const dot = from.dot(to);
+  return Math.atan2(axis.dot(cross), dot);
+}
+
+function angleToMatchNormal(from, to, axis) {
+  const angleSame = signedAngleAroundAxis(from, to, axis);
+  const angleOpp = signedAngleAroundAxis(from, to.clone().multiplyScalar(-1), axis);
+  const tmp = from.clone().applyAxisAngle(axis, angleSame);
+  const tmpOpp = from.clone().applyAxisAngle(axis, angleOpp);
+  return tmp.dot(to) >= tmpOpp.dot(to) ? angleSame : angleOpp;
+}
+
+function resolveSheetMetalParams(solid, opts = {}) {
+  const fallbackThickness = Number.isFinite(opts.thickness)
+    ? Number(opts.thickness)
+    : Number(solid?.userData?.sheetMetal?.thickness ?? solid?.userData?.sheetThickness ?? 0);
+  const fallbackRadius = Number.isFinite(opts.bendRadius)
+    ? Number(opts.bendRadius)
+    : Number(solid?.userData?.sheetMetal?.bendRadius ?? solid?.userData?.sheetBendRadius ?? 0);
+  const neutral = Number.isFinite(opts.kFactor)
+    ? Number(opts.kFactor)
+    : (Number.isFinite(opts.neutralFactor)
+      ? Number(opts.neutralFactor)
+      : Number(solid?.userData?.sheetMetal?.neutralFactor ?? solid?.userData?.sheetMetalNeutralFactor ?? 0.5));
+  return {
+    thickness: Number.isFinite(fallbackThickness) ? fallbackThickness : 0,
+    bendRadius: Number.isFinite(fallbackRadius) ? fallbackRadius : 0,
+    kFactor: Number.isFinite(neutral) ? neutral : 0.5,
+  };
+}
+
+function computeFaceStatsFromMesh(mesh) {
+  const positions = mesh?.vertProperties;
+  const triVerts = mesh?.triVerts;
+  const faceIDs = mesh?.faceID;
+  if (!positions || !triVerts || !faceIDs) return new Map();
+  const triCount = (triVerts.length / 3) | 0;
+  const stats = new Map();
+
+  const vA = new THREE.Vector3();
+  const vB = new THREE.Vector3();
+  const vC = new THREE.Vector3();
+  const vAB = new THREE.Vector3();
+  const vAC = new THREE.Vector3();
+  const n = new THREE.Vector3();
+  const centroid = new THREE.Vector3();
+
+  for (let t = 0; t < triCount; t++) {
+    const faceId = faceIDs[t];
+    let data = stats.get(faceId);
+    if (!data) {
+      data = { sum: new THREE.Vector3(), centroidSum: new THREE.Vector3(), area: 0, ref: null };
+      stats.set(faceId, data);
+    }
+    const base = t * 3;
+    const i0 = triVerts[base + 0];
+    const i1 = triVerts[base + 1];
+    const i2 = triVerts[base + 2];
+    vA.fromArray(positions, i0 * 3);
+    vB.fromArray(positions, i1 * 3);
+    vC.fromArray(positions, i2 * 3);
+    vAB.subVectors(vB, vA);
+    vAC.subVectors(vC, vA);
+    n.crossVectors(vAB, vAC);
+    const len = n.length();
+    if (len < EPS) continue;
+    const area = len * 0.5;
+    n.multiplyScalar(1 / len);
+    if (!data.ref) data.ref = n.clone();
+    else if (n.dot(data.ref) < 0) n.negate();
+    data.sum.addScaledVector(n, area);
+    centroid.copy(vA).add(vB).add(vC).multiplyScalar(1 / 3);
+    data.centroidSum.addScaledVector(centroid, area);
+    data.area += area;
+  }
+
+  const out = new Map();
+  for (const [faceId, data] of stats.entries()) {
+    const normal = data.sum.lengthSq() > EPS
+      ? data.sum.normalize()
+      : (data.ref ? data.ref.clone().normalize() : new THREE.Vector3(0, 1, 0));
+    const centroidFinal = data.area > EPS
+      ? data.centroidSum.multiplyScalar(1 / data.area)
+      : new THREE.Vector3();
+    out.set(faceId, { normal, centroid: centroidFinal, area: data.area });
+  }
+  return out;
+}
+
+function computeMeshBounds(positions) {
+  if (!positions || !positions.length) return new THREE.Box3();
+  const box = new THREE.Box3();
+  const v = new THREE.Vector3();
+  const count = (positions.length / 3) | 0;
+  for (let i = 0; i < count; i++) {
+    v.set(positions[i * 3 + 0], positions[i * 3 + 1], positions[i * 3 + 2]);
+    box.expandByPoint(v);
+  }
+  return box;
+}
+
+function buildBendVertexRemap({
+  mesh,
+  boundaries,
+  faceInfo,
+  planarFaceIds,
+  bendFaceIds,
+  faceNameToId,
+  epsilon,
+}) {
+  if (!mesh || !mesh.vertProperties) return { positions: null, remap: null };
+  const positions = Array.from(mesh.vertProperties);
+  const remap = new Map();
+  const bendPointMap = new Map();
+  const snap = Number.isFinite(epsilon) ? epsilon : 1e-5;
+
+  for (const boundary of boundaries || []) {
+    const faceAName = boundary?.faceA;
+    const faceBName = boundary?.faceB;
+    if (!faceAName || !faceBName) continue;
+    const faceAId = faceNameToId.get(faceAName);
+    const faceBId = faceNameToId.get(faceBName);
+    if (faceAId == null || faceBId == null) continue;
+    const isPlanarA = planarFaceIds.has(faceAId);
+    const isPlanarB = planarFaceIds.has(faceBId);
+    const isBendA = bendFaceIds.has(faceAId);
+    const isBendB = bendFaceIds.has(faceBId);
+    if (!(isPlanarA && isBendB) && !(isPlanarB && isBendA)) continue;
+
+    const bendId = isBendA ? faceAId : faceBId;
+    const bendMeta = faceInfo.get(bendId)?.meta || {};
+    let axisDir = readVec3(bendMeta.axis);
+    if (!axisDir) axisDir = deriveAxisFromBoundary(boundary);
+    if (!axisDir || axisDir.lengthSq() < EPS) continue;
+    axisDir.normalize();
+    let axisPoint = readVec3(bendMeta.center);
+    if (!axisPoint) axisPoint = derivePointFromBoundary(boundary);
+    if (!axisPoint) axisPoint = new THREE.Vector3();
+
+    let map = bendPointMap.get(bendId);
+    if (!map) { map = new Map(); bendPointMap.set(bendId, map); }
+
+    const indices = Array.isArray(boundary?.indices) ? boundary.indices : [];
+    for (const idx of indices) {
+      if (!Number.isFinite(idx)) continue;
+      if (remap.has(idx)) continue;
+      const px = positions[idx * 3 + 0];
+      const py = positions[idx * 3 + 1];
+      const pz = positions[idx * 3 + 2];
+      const p = new THREE.Vector3(px, py, pz);
+      const t = axisDir.dot(p.clone().sub(axisPoint));
+      const tSnap = Math.round(t / snap) * snap;
+      const key = `${bendId}|${tSnap.toFixed(6)}`;
+      let newIdx = map.get(key);
+      if (newIdx == null) {
+        const proj = axisPoint.clone().addScaledVector(axisDir, tSnap);
+        newIdx = (positions.length / 3) | 0;
+        positions.push(proj.x, proj.y, proj.z);
+        map.set(key, newIdx);
+      }
+      remap.set(idx, newIdx);
+    }
+  }
+
+  return {
+    positions,
+    remap,
+  };
+}
+
+function buildPlanarGroups({ planarFaceIds, faceInfo, faceStats, boundaries, bounds, opts }) {
+  const faceToGroup = new Map();
+  const groupNormals = new Map();
+
+  const diag = bounds?.isEmpty?.() ? 0 : bounds.getSize(new THREE.Vector3()).length();
+  const normalTol = Number.isFinite(opts.normalTol) ? opts.normalTol : 1e-3;
+  const distTol = Number.isFinite(opts.planeTol) ? opts.planeTol : Math.max(1e-6, diag * 1e-5);
+
+  const adjacency = new Map();
+  for (const boundary of boundaries || []) {
+    const faceAName = boundary?.faceA;
+    const faceBName = boundary?.faceB;
+    if (!faceAName || !faceBName) continue;
+    const faceAId = opts.faceNameToId?.get(faceAName);
+    const faceBId = opts.faceNameToId?.get(faceBName);
+    if (faceAId == null || faceBId == null) continue;
+    if (!planarFaceIds.has(faceAId) || !planarFaceIds.has(faceBId)) continue;
+    let list = adjacency.get(faceAId);
+    if (!list) { list = new Set(); adjacency.set(faceAId, list); }
+    list.add(faceBId);
+    list = adjacency.get(faceBId);
+    if (!list) { list = new Set(); adjacency.set(faceBId, list); }
+    list.add(faceAId);
+  }
+
+  let groupId = 0;
+  for (const faceId of planarFaceIds) {
+    if (faceToGroup.has(faceId)) continue;
+    const stack = [faceId];
+    faceToGroup.set(faceId, groupId);
+    while (stack.length) {
+      const current = stack.pop();
+      const neighbors = adjacency.get(current);
+      if (!neighbors) continue;
+      for (const neighbor of neighbors) {
+        if (faceToGroup.has(neighbor)) continue;
+        const infoA = faceInfo.get(current);
+        const infoB = faceInfo.get(neighbor);
+        if (infoA?.sheetType && infoB?.sheetType && infoA.sheetType !== infoB.sheetType) continue;
+        const statsA = faceStats.get(current);
+        const statsB = faceStats.get(neighbor);
+        if (!statsA || !statsB) continue;
+        const dot = statsA.normal.dot(statsB.normal);
+        if (dot < 1 - normalTol) continue;
+        const distA = statsA.normal.dot(statsA.centroid);
+        const distB = statsB.normal.dot(statsB.centroid);
+        if (Math.abs(distA - distB) > distTol) continue;
+        faceToGroup.set(neighbor, groupId);
+        stack.push(neighbor);
+      }
+    }
+    groupId += 1;
+  }
+
+  for (const [faceId, gid] of faceToGroup.entries()) {
+    const stats = faceStats.get(faceId);
+    if (!stats) continue;
+    const area = stats.area || 0;
+    if (!groupNormals.has(gid)) {
+      groupNormals.set(gid, stats.normal.clone().multiplyScalar(area));
+    } else {
+      groupNormals.get(gid).addScaledVector(stats.normal, area);
+    }
+  }
+
+  for (const [gid, normal] of groupNormals.entries()) {
+    if (normal.lengthSq() > EPS) normal.normalize();
+    else normal.set(0, 1, 0);
+  }
+
+  return { faceToGroup, groupNormals };
+}
+
+function buildGeometryFromMesh(mesh, planarFaceIds, faceToGroup, vertexRemap, positionsOverride) {
+  if (!mesh || !mesh.vertProperties || !mesh.triVerts || !mesh.faceID) return null;
+  const positions = positionsOverride
+    ? new Float32Array(positionsOverride)
+    : new Float32Array(mesh.vertProperties);
+  const triVerts = mesh.triVerts;
+  const faceIDs = mesh.faceID;
+  const triCount = (triVerts.length / 3) | 0;
+
+  const indices = [];
+  const faceIdsAttr = [];
+  for (let t = 0; t < triCount; t++) {
+    const faceId = faceIDs[t];
+    if (!planarFaceIds.has(faceId)) continue;
+    const groupId = faceToGroup?.get(faceId);
+    if (groupId == null) continue;
+    const base = t * 3;
+    const i0 = triVerts[base + 0];
+    const i1 = triVerts[base + 1];
+    const i2 = triVerts[base + 2];
+    indices.push(
+      vertexRemap?.get(i0) ?? i0,
+      vertexRemap?.get(i1) ?? i1,
+      vertexRemap?.get(i2) ?? i2,
+    );
+    faceIdsAttr.push(groupId);
+  }
+
+  if (!indices.length) return null;
+
+  const geometry = new THREE.BufferGeometry();
+  geometry.setAttribute('position', new THREE.BufferAttribute(positions, 3));
+  const indexArray = (positions.length / 3) > 65535
+    ? new Uint32Array(indices)
+    : new Uint16Array(indices);
+  geometry.setIndex(new THREE.BufferAttribute(indexArray, 1));
+  geometry.setAttribute('faceId', new THREE.BufferAttribute(new Uint32Array(faceIdsAttr), 1));
+  return geometry;
+}
+
+function buildInputsFromSolid(solid, opts = {}) {
+  if (!solid || typeof solid.getMesh !== 'function') return null;
+
+  const explicitGeometry = (opts.geometry instanceof THREE.BufferGeometry)
+    ? opts.geometry
+    : (solid.userData?.flatPatternGeometry || solid.userData?.sheetMetalFlatGeometry);
+  const explicitBends = Array.isArray(opts.bends)
+    ? opts.bends
+    : (solid.userData?.flatPatternBends || solid.userData?.sheetMetalBends);
+  if (explicitGeometry instanceof THREE.BufferGeometry && Array.isArray(explicitBends)) {
+    return {
+      geometry: explicitGeometry,
+      bends: explicitBends,
+      edgeExclusions: null,
+      warnings: [],
+    };
+  }
+
+  const mesh = solid.getMesh();
+  try {
+    if (!mesh || !mesh.vertProperties || !mesh.triVerts) return null;
+    const faceIDs = mesh.faceID;
+    if (!faceIDs || !faceIDs.length) return null;
+
+    const idToName = solid._idToFaceName instanceof Map ? solid._idToFaceName : new Map();
+    const faceNameToId = solid._faceNameToID instanceof Map ? solid._faceNameToID : new Map();
+    const planarFaceIds = new Set();
+    const bendFaceIds = new Set();
+    const planarBySide = {
+      [SHEET_METAL_FACE_TYPES.A]: new Set(),
+      [SHEET_METAL_FACE_TYPES.B]: new Set(),
+    };
+    const planarFallback = new Set();
+    const faceInfo = new Map();
+    const faceStats = computeFaceStatsFromMesh(mesh);
+    let areaA = 0;
+    let areaB = 0;
+
+    for (let t = 0; t < faceIDs.length; t++) {
+      const faceId = faceIDs[t];
+      if (faceInfo.has(faceId)) continue;
+      const faceName = idToName.get(faceId) || `FACE_${faceId}`;
+      let meta = {};
+      if (typeof solid.getFaceMetadata === 'function') {
+        try { meta = solid.getFaceMetadata(faceName) || {}; } catch { meta = {}; }
+      }
+      const sheetType = meta.sheetMetalFaceType || null;
+      const surfaceType = meta.type || null;
+      const stats = faceStats.get(faceId);
+      if (sheetType === SHEET_METAL_FACE_TYPES.A || sheetType === SHEET_METAL_FACE_TYPES.B) {
+        planarBySide[sheetType].add(faceId);
+        const area = stats?.area || 0;
+        if (sheetType === SHEET_METAL_FACE_TYPES.A) areaA += area;
+        if (sheetType === SHEET_METAL_FACE_TYPES.B) areaB += area;
+      }
+      if (surfaceType && BEND_SURFACE_TYPES.has(surfaceType)) {
+        bendFaceIds.add(faceId);
+      }
+      if (!sheetType && !surfaceType && stats) {
+        planarFallback.add(faceId);
+      }
+      faceInfo.set(faceId, { faceId, faceName, meta, sheetType, surfaceType });
+    }
+
+    const hasA = planarBySide[SHEET_METAL_FACE_TYPES.A].size > 0;
+    const hasB = planarBySide[SHEET_METAL_FACE_TYPES.B].size > 0;
+    const forcedSide = opts.forceSide === SHEET_METAL_FACE_TYPES.A || opts.forceSide === SHEET_METAL_FACE_TYPES.B
+      ? opts.forceSide
+      : null;
+    let chosenSide = null;
+    if (forcedSide) {
+      chosenSide = forcedSide;
+    } else if (hasA || hasB) {
+      const prefer = (areaA >= areaB) ? SHEET_METAL_FACE_TYPES.A : SHEET_METAL_FACE_TYPES.B;
+      chosenSide = planarBySide[prefer].size ? prefer : (hasA ? SHEET_METAL_FACE_TYPES.A : SHEET_METAL_FACE_TYPES.B);
+    }
+    if (chosenSide) {
+      for (const id of planarBySide[chosenSide]) planarFaceIds.add(id);
+    } else {
+      for (const id of planarFallback) planarFaceIds.add(id);
+    }
+
+    const boundaries = (typeof solid.getBoundaryEdgePolylines === 'function')
+      ? (solid.getBoundaryEdgePolylines() || [])
+      : [];
+    const bounds = computeMeshBounds(mesh.vertProperties);
+    const useExplicitBends = Array.isArray(opts.bends) && opts.bends.length;
+    let faceToGroup;
+    let groupNormals;
+    if (useExplicitBends) {
+      faceToGroup = new Map();
+      groupNormals = new Map();
+      for (const faceId of planarFaceIds) {
+        faceToGroup.set(faceId, faceId);
+        const stats = faceStats.get(faceId);
+        if (stats?.normal) groupNormals.set(faceId, stats.normal.clone());
+      }
+    } else {
+      const grouped = buildPlanarGroups({
+        planarFaceIds,
+        faceInfo,
+        faceStats,
+        boundaries,
+        bounds,
+        opts: { normalTol: opts.normalTol, planeTol: opts.planeTol, faceNameToId },
+      });
+      faceToGroup = grouped.faceToGroup;
+      groupNormals = grouped.groupNormals;
+    }
+
+    let remap = null;
+    let positionsOverride = null;
+    if (!useExplicitBends) {
+      const remapData = buildBendVertexRemap({
+        mesh,
+        boundaries,
+        faceInfo,
+        planarFaceIds,
+        bendFaceIds,
+        faceNameToId,
+        epsilon: opts.epsilon,
+      });
+      remap = remapData.remap;
+      positionsOverride = remapData.positions;
+    }
+
+    const geometry = buildGeometryFromMesh(mesh, planarFaceIds, faceToGroup, remap, positionsOverride);
+    if (!geometry) return null;
+
+    const params = resolveSheetMetalParams(solid, opts);
+    const edgeExclusions = new Set();
+    const bendAdj = new Map();
+
+    if (boundaries && boundaries.length) {
+      for (const boundary of boundaries) {
+        const faceAName = boundary?.faceA;
+        const faceBName = boundary?.faceB;
+        if (!faceAName || !faceBName) continue;
+        const faceAId = faceNameToId.get(faceAName);
+        const faceBId = faceNameToId.get(faceBName);
+        if (faceAId == null || faceBId == null) continue;
+
+        const isPlanarA = planarFaceIds.has(faceAId);
+        const isPlanarB = planarFaceIds.has(faceBId);
+        const isBendA = bendFaceIds.has(faceAId);
+        const isBendB = bendFaceIds.has(faceBId);
+
+        if ((isBendA && isPlanarB) || (isBendB && isPlanarA)) {
+          const bendId = isBendA ? faceAId : faceBId;
+          const planarId = isPlanarA ? faceAId : faceBId;
+          const groupId = faceToGroup.get(planarId);
+          if (groupId == null) continue;
+          const length = polylineLength(boundary?.positions);
+          let byPlanar = bendAdj.get(bendId);
+          if (!byPlanar) { byPlanar = new Map(); bendAdj.set(bendId, byPlanar); }
+          const prev = byPlanar.get(groupId);
+          if (!prev || length > prev.length) {
+            byPlanar.set(groupId, { length, boundary });
+          }
+
+          const indices = Array.isArray(boundary?.indices) ? boundary.indices : [];
+          for (let i = 1; i < indices.length; i++) {
+            const aRaw = indices[i - 1];
+            const bRaw = indices[i];
+            const a = remap?.get(aRaw) ?? aRaw;
+            const b = remap?.get(bRaw) ?? bRaw;
+            if (Number.isFinite(a) && Number.isFinite(b) && a !== b) {
+              edgeExclusions.add(makeEdgeKey(a, b));
+            }
+          }
+        }
+
+        // Note: edges between planar faces are handled by bend metadata exclusion in unfold.
+      }
+    }
+
+    const bends = Array.isArray(explicitBends)
+      ? explicitBends
+      : [];
+
+    if (!bends.length) {
+      for (const [bendFaceId, neighbors] of bendAdj.entries()) {
+        const list = Array.from(neighbors.entries()).map(([planarId, data]) => ({
+          planarId,
+          length: data.length,
+          boundary: data.boundary,
+        })).sort((a, b) => b.length - a.length);
+        if (list.length < 2) continue;
+        const aFaceId = list[0].planarId;
+        const bFaceId = list[1].planarId;
+        if (aFaceId === bFaceId) continue;
+        const bendInfo = faceInfo.get(bendFaceId);
+        const meta = bendInfo?.meta || {};
+        let axisDir = readVec3(meta.axis);
+        if (!axisDir) axisDir = deriveAxisFromBoundary(list[0].boundary);
+        if (!axisDir || axisDir.lengthSq() < EPS) continue;
+        axisDir.normalize();
+        let axisPoint = readVec3(meta.center);
+        if (!axisPoint) axisPoint = derivePointFromBoundary(list[0].boundary);
+        if (!axisPoint) axisPoint = new THREE.Vector3();
+
+        const nA = groupNormals.get(aFaceId);
+        const nB = groupNormals.get(bFaceId);
+        let angleRad = 0;
+        if (nA && nB) {
+          angleRad = angleToMatchNormal(nA, nB, axisDir);
+        }
+
+        const radius = Number.isFinite(meta.radius) ? Number(meta.radius) : params.bendRadius;
+        const bend = {
+          bendId: bendInfo?.faceName || bendFaceId,
+          aFaceId,
+          bFaceId,
+          axisPoint,
+          axisDir,
+          angleRad,
+          radius: Number.isFinite(radius) ? radius : 0,
+          thickness: params.thickness,
+          kFactor: params.kFactor,
+          upDown: angleRad >= 0 ? 'up' : 'down',
+        };
+        bends.push(bend);
+      }
+    }
+
+    return {
+      geometry,
+      bends,
+      edgeExclusions,
+      warnings: [],
+      meta: {
+        chosenSide: chosenSide || null,
+        hasA,
+        hasB,
+      },
+    };
+  } finally {
+    try { if (mesh && typeof mesh.delete === 'function') mesh.delete(); } catch { }
+  }
+}
+
+function scoreFlatPattern(flatPattern) {
+  if (!flatPattern) return -1;
+  const outlines = Array.isArray(flatPattern.outlines) ? flatPattern.outlines.length : 0;
+  const holes = Array.isArray(flatPattern.holes) ? flatPattern.holes.length : 0;
+  const bends = Array.isArray(flatPattern.bendLines) ? flatPattern.bendLines.length : 0;
+  return outlines * 1000 + bends * 10 - holes;
+}
+
+function buildFlatPatternEntry(solid, opts = {}, index = 0) {
+  const name = solid?.name || `SHEET_${index + 1}`;
+  const tryBuild = (localOpts) => {
+    const inputs = buildInputsFromSolid(solid, localOpts);
+    if (!inputs || !inputs.geometry) return null;
+    const options = {
+      rootFaceId: localOpts.rootFaceId,
+      epsilon: localOpts.epsilon,
+      clipExtent: localOpts.clipExtent,
+      edgeExclusions: inputs.edgeExclusions,
+    };
+    const flatPattern = unfoldSheetMetal(inputs.geometry, inputs.bends || [], options);
+    const svg = exportFlatPatternToSVG(flatPattern, {
+      includeBends: localOpts.includeBends !== false,
+      scale: localOpts.scale,
+      padding: localOpts.padding,
+      flipY: localOpts.flipY,
+    });
+    return {
+      name,
+      flatPattern,
+      svg,
+      warnings: inputs.warnings || [],
+      meta: inputs.meta || null,
+    };
+  };
+
+  const primary = tryBuild(opts);
+  if (!primary) {
+    return {
+      name,
+      flatPattern: null,
+      svg: null,
+      warnings: ['No flat pattern inputs available for this solid.'],
+    };
+  }
+
+  const hasA = primary.meta?.hasA;
+  const hasB = primary.meta?.hasB;
+  if (opts.forceSide || !hasA || !hasB) return primary;
+
+  const altSide = primary.meta?.chosenSide === SHEET_METAL_FACE_TYPES.A
+    ? SHEET_METAL_FACE_TYPES.B
+    : SHEET_METAL_FACE_TYPES.A;
+  const alternate = tryBuild({ ...opts, forceSide: altSide });
+  if (!alternate) return primary;
+
+  const scorePrimary = scoreFlatPattern(primary.flatPattern);
+  const scoreAlternate = scoreFlatPattern(alternate.flatPattern);
+  return scoreAlternate > scorePrimary ? alternate : primary;
+}
+
+export function buildSheetMetalFlatPatternSolids(solids, opts = {}) {
+  const list = Array.isArray(solids) ? solids : [];
+  const entries = [];
+  for (let i = 0; i < list.length; i++) {
+    const solid = list[i];
+    if (!solid || typeof solid.getMesh !== 'function') continue;
+    const entry = buildFlatPatternEntry(solid, opts, i);
+    if (entry) entries.push(entry);
+  }
+  return entries;
+}
+
+export function buildSheetMetalFlatPatternSvgs(solids, opts = {}) {
+  const entries = buildSheetMetalFlatPatternSolids(solids, opts);
+  return entries.filter((entry) => !!entry?.svg).map((entry) => ({
+    name: entry.name,
+    svg: entry.svg,
+    flatPattern: entry.flatPattern,
+    warnings: entry.warnings,
+  }));
+}