brepjs-sheetmetal 0.1.0

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package/README.md

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+# brepjs-sheetmetal
+
+> Experimental, unpublished satellite package.
+
+A sheet-metal CAD domain for [brepjs](https://github.com/andymai/brepjs). It authors parametric
+sheet-metal parts (flange/bend features), auto-miters corners, folds to 3D, and unfolds to a flat
+pattern for fabrication.
+
+Pipeline: **author part → auto-miter corners → fold to 3D → unfold to flat pattern → export DXF/STEP/GLB + bend report.**
+
+## Scope
+
+Straight (cylindrical) bends, authoring our own parts (not unfolding foreign solids). The bend model is
+K-factor based by default, with optional **shop bend tables** (see below) for parts that develop per a
+press-brake's measured allowance/deduction values.
+
+- Bend allowance: `BA = (π/180)·|angle|·(R + K·T)`, or interpolated from a referenced bend table.
+- Defaults: units are mm; K-factor `0.44`; inner radius `= thickness`.
+
+Authoring supports arbitrary bend trees: flanges off any of the four base edges, **chained
+flange-off-flange** bends (U-channels, Z-profiles, box walls), **up/down** fold direction, and
+**partial/offset** flanges (more than one flange per edge). Closed profiles (tubes/boxes) author a seam
+edge that the unfold leaves uncut as a `SEAM_CUT`, flattening into a valid connected pattern.
+
+## Status
+
+| Area            | State                                                                                        |
+| --------------- | -------------------------------------------------------------------------------------------- |
+| Authoring       | 4-edge flanges, chained bends, up/down, partial/offset flanges, closed-box seams             |
+| Unfold          | recursive BFS tree-walk → rectilinear-union flat pattern + bend lines + developed area       |
+| Fold            | `FlatInput` region-tree → 3D part (inverse of unfold); round-trips `unfold(fold)`            |
+| Reliefs         | bend reliefs (slots at partial-flange bend-line ends), corner reliefs (notch at a corner)    |
+| Cutouts         | holes / slots (rect + obround) / polygons punched on the base or a folded flange             |
+| Tabs / joints   | additive edge tabs, self-fixturing tab-and-slot joints (tab + matching mating slot)          |
+| Form features   | louvers (3-side cut + formed flap), embosses / dimples (round raised / recessed forms)       |
+| Contour flange  | open line/arc profile swept along a base edge (multi-bend section); EXACT development        |
+| Lofted flange   | ruled transition between two open profiles; triangulated development (exact if developable)  |
+| Hems            | edge folded back ~180°+ (closed / open / teardrop / rolled); EXACT development               |
+| Jogs            | two opposite bends stepping a flat by a Z-offset (joggle); EXACT development                 |
+| Bend tables     | shop allowance/deduction tables, angle-linear + thickness×radius-bilinear interp, clamp-warn |
+| Miter / outputs | auto corner-miter, multi-layer DXF (incl. FORM layer), JSON bend report, warnings            |
+| API             | functional `*Fns` → short-named `api.ts` → fluent `sheetMetal()` facade                      |
+
+`fold(input: FlatInput)` folds a flat pattern back up into a 3D part, the inverse of `unfold`. A
+`FlatInput` is a region-tree (a base rectangle plus child fold regions, each with a fold line, angle,
+direction, and bend rule), the inverse of the unfold layout. `patternToFlatInput(pattern, { thickness,
+ruleFor })` recovers that region-tree from the **2D flat-pattern geometry alone** (the developed outline
+wire and bend-line edges), reading real coordinates back out with the public `getEdges` / `curveStartPoint`
+/ `curveEndPoint` readers; only the bend rule (which a flat pattern cannot encode) is a supplied input.
+`partToFlatInput(part)` chains `unfold` → `patternToFlatInput`, so `fold(partToFlatInput(part))` round-trips
+volume, validity, and bend/flange counts through the 2D geometry, making the round-trip a genuine,
+non-circular oracle. Fold reuses the forward authoring bend geometry wholesale (no duplicated bend math),
+and rides SEAM_CUT / MIN_RADIUS warnings inside the Ok payload.
+
+## Reliefs
+
+Multi-bend parts tear or collide at corners unless material is relieved. Reliefs are recorded features
+(like corner miters): cut from the folded 3D solid and replayed by `unfold` as 2D notches subtracted from
+the developed outline (so they ride in the DXF `OUTLINE` layer and shrink `developedArea`).
+
+- `addBendRelief(part, flangeId, spec?)` cuts a slot at each **mid-edge end** of a partial/offset flange's
+  bend line, the ends that don't reach the parent-edge endpoint, where the parent material would tear.
+  `autoBendReliefs(part, spec?)` adds one to every partial-span flange (full-span flanges are skipped).
+- `cornerRelief(part, flangeIdA, flangeIdB, spec?)` cuts a square notch centred on the shared corner of two
+  adjacent flanges, the notch alternative to a 45° miter. The square side is `spec.width` when given, else
+  the depth clearance. It records the corner as resolved, so the `COLLISION` warning the un-relieved corner
+  raised goes away.
+
+A `ReliefSpec` is `{ shape: 'rectangular' | 'obround'; width?; depth? }`. Defaults: `width ≈ thickness`,
+`depth ≈ developedLength(bend) + thickness`. `obround` records the rounded-slot intent; the developed notch
+and 3D cut are rectangular for both shapes in this version. Reliefs round-trip through `fold` via a
+`FoldRegion.bendRelief` field; the strict geometric round-trip oracle (`partToFlatInput → fold`) skips
+relief'd parts because a notched outline is not a plain rectangle the parser can re-derive (same as mitered
+parts).
+
+## Cutouts
+
+Holes, slots, and polygon cutouts are 2D features punched through a flat region's thickness. They survive
+fold/unfold: each appears in the 3D solid, in the flat pattern (`FlatPattern.holes`, one closed wire per
+cutout), and in the DXF (a `CUTOUT` layer). The outer outline is unchanged; cutouts are interior loops.
+
+A `CutoutSpec` names the `region` (a flange id, or `'base'`/`'root'` for the base flat) and places the
+feature in that region's **local** frame: `(0, 0)` is the region's near corner, `+x` runs along the region's
+`u` axis and `+y` along its `v` axis. The discriminated union is `hole` (`{ x, y, diameter }`), `slot`
+(`{ x, y, length, width, angleDeg?, round? }`, where `round` makes the ends semicircular/obround), or `polygon`
+(`{ points: [x, y][] }`).
+
+- `addCutout(part, spec)` / `addHole(part, region, x, y, diameter)` / `addSlot(part, region, opts)` /
+  `addPolygonCutout(part, region, points)` cut the feature through the sheet on the **correct face**: the 2D
+  profile is built in region-local coords, then placed via the region's world frame (origin/u/v/n), so a
+  hole authored on a folded flange lands on the flange face, not the base plane. Rejects a feature outside
+  the region (`CUTOUT_OUT_OF_BOUNDS`) and guards a valid, single-bodied result (`CUTOUT_SEVERED_SOLID`).
+- `unfold` emits the matching developed loop at the cutout's flat-pattern location (mapped through the same
+  region's developed frame) and drops `developedArea` by the cutout areas.
+
+Cutouts round-trip through `fold` via `FoldRegion.cutouts` (and `FlatInput.baseCutouts` for the base):
+`partToFlatInput(part)` carries the region-local specs across, so `fold(partToFlatInput(part))` reproduces a
+cutout'd part's volume. Unlike notched reliefs, cutouts don't change the outer outline, so a cutout'd part
+still round-trips through the strict outline oracle.
+
+## Tabs and tab-and-slot joints
+
+A **tab** is the additive counterpart of a cutout: a rectangular protrusion of material extending
+**outward** from a flat region's edge. `addTab(part, { region, side, offset, width, length })` builds the
+tab as a region-local rectangle just past the chosen `side`, places it on the correct folded face via the
+region's world frame, extrudes it through the sheet thickness and **fuses** it on, so the volume rises by
+`width · length · thickness`. The same rectangle is mapped through the region's developed frame and recorded
+as a `TabFeature`, so `unfold` **extends the outer outline** by the protrusion and grows `developedArea` by
+the tab area. Guards a valid, single-bodied result (`TAB_INVALID_SOLID`) and rejects a tab overhanging its
+edge (`TAB_OUT_OF_BOUNDS`).
+
+`tabAndSlot(part, tab, { region, x, y, clearance? })` is the headline self-locating joint: it fuses a tab on
+one region **and** punches a matching **slot cutout** on the mating region, sized so the tab's cross-section
+(`width × thickness`) inserts into the slot. The slot is `tab.width + clearance` long by `thickness +
+clearance` wide, always strictly larger than the tab cross-section, so the joint mates (clearance defaults
+to `0.1` mm). Use it to make boxes/enclosures that self-fixture before welding.
+
+Tabs ride through `fold` via `FoldRegion.tabs` / `FlatInput.baseTabs`, so `fold` re-fuses them and a tab'd
+part folds back into the same volume. Like cutouts and forms, a tab carries its region-local spec, so
+`partToFlatInput` re-attaches it onto the recovered region and `fold(partToFlatInput(part))` round-trips a
+tab'd part's volume through the strict oracle. Although a tab protrudes the outer outline, the parser
+recovers the base/flange rectangles from the bend lines and the unprotruded edges, so the protrusion does
+not corrupt region recovery (a tab on an unmappable region fails loudly with `TAB_REGION_UNMAPPED` rather
+than being silently dropped).
+
+## Form features (louvers, embosses, dimples)
+
+Form features are **locally formed**: they neither remove nor add net material, so the developed **outline
+and area are unchanged**; the flat pattern instead carries the fabrication markers on a `FORM` DXF layer.
+
+- `louver(part, { region, x, y, length, width, height, direction? })`: a vent cut on three sides with the
+  flap formed up along the hinge. In the **flat pattern** it emits the three cut sides as an **open** cut
+  path in `FlatPattern.formCuts` (the fabricator cuts three of the footprint's four sides, all but the
+  hinge) plus the hinge fold line in `FlatPattern.formHinges`, so a fabricator cuts the U and folds the flap
+  about the uncut hinge. The cut path is emitted as an open LWPOLYLINE on the DXF `FORM` layer (not a closed
+  rectangle, which would drop the flap out).
+- `emboss(part, { region, x, y, diameter, height, kind: 'emboss' | 'dimple' })`: a round local form, raised
+  (`emboss`) or recessed (`dimple`). The footprint circle is emitted as a marker (`FlatPattern.formMarkers`).
+
+**3D fidelity (simplified, documented).** The public CSG-only API makes true sheet forming (bending the flap
+continuous with the parent, or stretch-forming a spherical cap) impractical, so the 3D representations are
+deliberately simplified while keeping a **valid single solid**; the flat pattern is the fabrication-critical
+output:
+
+- _Louver_: the vent opening (`length × width`) is cut fully through the sheet, and the formed flap is
+  represented as a thin plate hinged on one side and tilted up to `height`, fused at the hinge so the result
+  stays one body. (True forming keeps the flap material continuous with the parent.)
+- _Emboss_: a short cylinder fused onto the formed face (raised by `height`). _Dimple_: a shallow cylinder
+  recess cut into the formed face (recessed by `height`, never through; rejected if `height ≥ thickness`).
+  The flat-topped round approximates a true spherical/conical form so the solid stays valid.
+
+Forms ride through `fold` via `FoldRegion.forms` / `FlatInput.baseForms`. Because they are material-neutral
+they don't change the outline, so a **formed part still round-trips** through the strict outline oracle
+(`partToFlatInput` carries the region-local form specs across, exactly as it does for cutouts).
+
+## Contour & lofted/ruled transition flanges
+
+Two profile-driven flanges extend authoring beyond single straight bends:
+
+- `contourFlange(part, { id, side, profile, rule?, offset?, width? })`: an **open 2D profile** (alternating
+  `{ kind: 'line', length }` flats and `{ kind: 'arc', radius, angleDeg, direction }` bends) swept along a
+  straight base edge into a multi-bend cross-section (a return, a hat/top-hat, a J). Each arc becomes a
+  recorded `BendFeature` (id `contour::<flange>::<n>`) and chains frame-to-frame exactly as flange-off-flange
+  bends do. The **development is EXACT**: the developed strip length is the sum of each segment's developed
+  length (lines: `length`; arcs: the canonical `developedLength` = `(π/180)·|angle|·(R + K·T)`). The unfold
+  lays the strip out straight along the base edge with one bend line per arc at its exact cumulative
+  arc-length offset.
+- `loftedFlange(part, { id, profileA, profileB, height, thickness? })`: a **ruled transition** between two
+  parallel open profiles (`profileA` at z=0, `profileB` at z=`height`, equal vertex counts), thickened to a
+  valid solid by triangulating each quad of the ruled surface and extruding each triangle. The
+  **development is by triangulation**, the standard sheet-metal transition development: each quad is split
+  along a diagonal into two triangles laid out flat preserving their true 3D edge lengths. For a genuinely
+  **developable** transition (planar quads / single-curvature) this is **exact to tolerance**; for a
+  non-developable (twisted) transition it is an **approximation**, and the unfold emits a
+  `DEVELOPMENT_APPROXIMATE` warning (inside the `Ok` payload). The triangulated boundary is emitted as a
+  valid closed wire in `FlatPattern.loftedDevelopments`.
+
+Both flanges have **non-rectilinear** developments, so, like miters and tabs, they sit outside the strict
+`patternToFlatInput` outline oracle: verification leans on developed-length/area invariants and solid
+validity rather than a fold round-trip. The contour flange's developed strip still joins the rectilinear
+outline union; the lofted flange's triangulated blank is a separate developed boundary.
+
+## Hems & jogs
+
+Hems and jogs are multi-bend edge features built on the same frame-to-frame profile chainer as the contour
+flange, so their developments are **EXACT** (Σ segment developed lengths, via the table-aware
+`developedLength`). Both attach to any flat **region**, the base (`'base'`/`'root'`) or a named flange,
+edge, record their curl/step sub-bends as `hem::<id>::<n>` / `jog::<id>::<n>` `BendFeature`s (skipped by the
+feature-tree spanning walk, like `contour::` bends), and lay their developed strip out straight along the
+region edge with one bend line per sub-bend.
+
+- `hem(part, { region, side, type, length?, radius?, gap?, offset?, width?, rule? })` folds a region edge
+  back onto its parent. Four `type`s set the curl angle and the gap:
+  - **`closed`**: a tight ~180° fold, the return flat against the parent. The curl radius is inflated by a
+    small **HAIR** clearance (0.05 mm) so the fused solid stays valid (a true zero-gap fold makes the curl's
+    inner cylinder coincide with the parent face → a self-touching, non-manifold solid). `length` is the
+    return-leg length (must be ≥ one thickness).
+  - **`open`**: a ~180° fold with a clear `gap` (default = `radius`) between the return and the parent; the
+    curl radius is sized from the gap, so its developed curl length is the exact 180° allowance at that radius.
+  - **`teardrop`**: a >180° (~210°) curl leaving a small teardrop opening, then a short return.
+  - **`rolled`**: a full ~270° circular roll (a curled / safe edge); no flat return.
+
+  The curl is split into ≤120° sub-arcs (the bend-patch wedge degenerates at ≥180°), each a recorded
+  sub-bend; the bend allowance is linear in angle, so Σ sub-arc allowances == the single-curl allowance. The
+  **developed length** is Σ curl allowances + the return length, laid out straight past the edge.
+
+- `jog(part, { region, side, position, offsetHeight, angle?, runOut?, radius?, offset?, width?, rule? })`
+  steps a flat by `offsetHeight` perpendicular to its plane with **two opposite bends** (`+θ` then `−θ`,
+  `angle` default 45°), then continues parallel. The connecting step run is solved so the two arcs' rise plus
+  the step rise equals `offsetHeight` exactly; the resulting run-out bottom face sits exactly `offsetHeight`
+  above the base bottom face (verified by measurement, not just construction). The flat carries the **two
+  bend lines** (one `up`, one `down`); the **developed length** is `position + 2·allowance + stepRun +
+runOut`. `offsetHeight` must exceed the bends' own rise `(T + 2R)(1 − cos θ)`, else the jog is rejected.
+
+Like the contour/lofted flanges, hems and jogs have non-rectilinear developments and so sit outside the
+strict `partToFlatInput → fold` round-trip oracle; verification leans on developed-length invariants, the
+measured jog offset, and solid validity.
+
+## Nesting
+
+`nest(patterns, { sheet, margin?, spacing?, allowRotation?, strategy? })` arranges a set of developed flat
+patterns onto stock sheets to reduce waste, returning `Result<NestResult>` (`{ sheets, unplaced, warnings }`).
+Each sheet carries its `placements` (`{ patternIndex, x, y, rotationDeg }`) and a `utilization`.
+`nestToDXF(result, patterns, sheetIndex)` then emits one fabrication-ready, multi-layer DXF per sheet,
+translating and rotating every placed pattern (outline + bend lines + holes + forms) onto the sheet.
+
+Two strategies are available via `strategy`:
+
+### `strategy: "bbox"` (default): bounding-box nesting
+
+Packs each part as its axis-aligned **outline bounding box**, so parts do **not** interlock: a concave or
+L-shaped part reserves its full rectangular footprint and leaves the in-bbox waste unused. `rotationDeg` is
+`0` or `90`. This remains the default so existing callers are unchanged.
+
+- **Algorithm.** A shelf (level) packing heuristic. Parts are sorted largest-first (by bbox height, then area)
+  and placed left-to-right into horizontal shelves; a new shelf opens below when the current row fills, and a
+  **new sheet** opens when the next shelf would overflow the usable height.
+- **Rotation.** With `allowRotation`, each part is tried at `0°` and `90°` and the orientation that fits (or
+  packs shorter) is kept.
+- **Utilization.** Σ placed part **bounding-box** areas ÷ usable-sheet area, a conservative lower bound that
+  does not credit inter-part gaps or intra-bbox waste.
+
+### `strategy: "nfp"`: true-shape (no-fit-polygon) nesting
+
+Packs the actual **outline polygons** so concave parts interlock; an L-shaped part nests a rotated copy into
+its notch, fitting more material per sheet than bbox packing ever can. `rotationDeg` may be `0/90/180/270`.
+
+> **Heuristic, not optimal.** The nfp packer is a **bottom-left-fill** heuristic (largest-first, with a
+> discretised raster scan over each part's orientations). It finds good interlocks but is **not** a provably
+> optimal solver; a different part order or finer rotation set may pack tighter. What it guarantees: placed
+> outline polygons never overlap (within `spacing`), all placements stay inside `[margin, sheet − margin]`, an
+> oversized part goes to `unplaced` with a `PART_TOO_LARGE` warning (never dropped, never an infinite loop).
+
+- **Correctness backbone.** Overlap is tested at the **polygon** level: two outlines overlap iff any edges
+  cross **or** one contains a vertex of the other (full containment), with a configurable `spacing` clearance.
+  A bbox-only check would let a part collide with a concave neighbour, so the true outline is always used.
+- **Utilization.** Σ placed part **outline-polygon** areas ÷ usable-sheet area, so an L-shaped part credits
+  only its true material; the two strategies' utilizations are directly comparable on the same parts.
+- **Geometry assumption.** Outlines are read as straight-edged polylines (one vertex per edge start point);
+  arc edges are approximated by their endpoints, the same assumption the DXF/SVG writers and the bbox nester
+  make.
+
+On a set of identical L-shaped parts, `"nfp"` interlocks them and typically uses roughly **half the sheets** of
+`"bbox"` (see the snapshot harness's `nfp vs bbox` demo).
+
+```ts
+const patterns = parts.map((p) => unfold(p).value.pattern);
+
+// Default bounding-box nesting:
+const bbox = nest(patterns, {
+  sheet: { width: 1250, height: 2500 },
+  margin: 5,
+  spacing: 3,
+  allowRotation: true,
+});
+
+// True-shape nesting - interlocks concave parts for higher utilization:
+const nfp = nest(patterns, {
+  sheet: { width: 1250, height: 2500 },
+  margin: 5,
+  spacing: 3,
+  allowRotation: true,
+  strategy: 'nfp',
+});
+
+const dxf = nestToDXF(nfp.value, patterns, 0); // fabrication-ready DXF for sheet 0
+```
+
+## Foreign-solid import & unfold
+
+`unfoldSolid(solid, { kFactor? })` (fluent: `fromSolid(solid).unfold()`) flattens an **arbitrary imported
+sheet-metal solid that has no feature tree** by detecting its geometry numerically, the reverse of the
+authored path. It reads only the B-rep:
+
+- **Classify faces** by surface type: planar faces are panel faces, cylindrical faces are bend faces. Any
+  other surface type (cone, sphere, spline, …) is reported `UNSUPPORTED_FACE` and skipped (the unfold never
+  silently invents a flat for an unrecognised face).
+- **Pair flats**: the two large parallel planar faces of a panel, a sheet thickness apart, are the
+  mid-surface flat. Thickness is detected as the smallest opposed-planar-pair gap.
+- **Fit bends**: `fitCylinder(face)` recovers a bend's axis + radius + swept angle from sampled points and
+  normals. The axis direction is the common perpendicular of the sampled normals (every cylinder normal is
+  ⟂ the axis), recovered as the sign-aligned average of cross products of non-parallel normal pairs; the
+  axis line and radius come from a least-squares circle fit of the points projected onto the plane ⟂ axis;
+  the radius is the mean point-to-axis distance. A fit whose residual exceeds tolerance is rejected (warned).
+  Recovery is high-precision: radius and axis of a known `cylinder()` primitive are recovered to ~1e-6.
+- **Build the bend graph** (flats = nodes; a bend connects the two flats it shares edges with), take a
+  spanning tree from a root flat, and turn non-tree bends into seam cuts (`SEAM_CUT`, warned).
+- **Unfold** by walking the tree, replacing each cylindrical region with a developed strip of length
+  `developedLength(angle, thickness, { innerRadius, kFactor })`. Because a foreign solid carries no material
+  K-factor, the default is the **mid-surface neutral axis (K = 0.5)**; pass `{ kFactor }` to match a known
+  material. Bend direction (up/down) is read from the cylinder centre relative to the parent flat.
+
+**Supported class**: roughly-uniform-thickness solids whose panels are **planar** and whose bends are
+**cylindrical** (straight bends). Outside this class the unfold **warns rather than mis-unfolding**:
+non-uniform thickness, conical/spline bend faces, non-manifold / non-sheet topology, and faces that don't
+fit a cylinder within tolerance all surface as warnings inside the `Ok` payload (or a clear `Err` when no
+sheet-metal structure is detected at all, e.g. a bare sphere). The detection is validated by an oracle:
+author a part, take only its `.solid`, run `unfoldSolid`, and confirm the detected unfold reproduces the
+authored unfold's developed area, bend count, flat count, and total flat bbox (single bend, L-bracket,
+U-channel), reading only the solid, never the feature tree.
+
+## Bend tables
+
+By default a bend develops by the K-factor formula `BA = (π/180)·|angle|·(R + K·T)`. A `BendRule` may
+instead reference a **shop bend table** by id (`rule.bendTableRef`), in which case the developed length is
+**interpolated from the table**: linear in bend angle, bilinear across thickness × inner radius (with
+nearest-radius substitution for sparse one-radius-per-gauge tables), clamping to the nearest tabulated
+entry outside the table's range (and emitting a `MIN_RADIUS` unfold warning rather than extrapolating).
+
+A table is `{ id, kind: 'allowance' | 'deduction', rows: { thickness, radius, angleDeg, value }[] }`. An
+`allowance` table tabulates the developed arc length directly; a `deduction` table tabulates the bend
+deduction and is converted on lookup via the outside-setback relation `OSSB = (R+T)·tan(θ/2)`,
+`BD = 2·OSSB − BA` ⇒ `BA = 2·OSSB − BD` (for a 90° bend, `OSSB = R+T`).
+
+Resolution precedence at the single resolution point (`resolveBendAllowance`, which `developedLength`
+delegates to): **(1) `bendTableRef` table → (2) explicit `rule.allowance` override → (3) K-factor formula**.
+Parts with no `bendTableRef` are byte-for-byte unchanged. Two starter air-bend tables ship auto-registered
+on first access (`steel-airbend` (mild steel) and `aluminum-airbend` (5052-H32)) with published 90°
+allowances scaled across {30, 60, 90, 120}° (sources: SheetMetal.Me charts, Machinery's Handbook 29th ed.).
+
+```ts
+import { registerBendTable, author, unfold } from 'brepjs-sheetmetal';
+
+registerBendTable({
+  id: 'my-shop-steel',
+  kind: 'allowance',
+  rows: [{ thickness: 1.52, radius: 1.5, angleDeg: 90, value: 3.63 }],
+});
+
+const part = author({
+  thickness: 1.52,
+  base: { length: 40, width: 40 },
+  flanges: [
+    {
+      id: 'fx',
+      length: 18,
+      angleDeg: 90,
+      side: 'xmax',
+      rule: { innerRadius: 1.5, kFactor: 0.44, bendTableRef: 'my-shop-steel' },
+    },
+  ],
+});
+// unfold(part.value) now develops the bend at BA = 3.63 mm (the table), not (π/2)·(R + K·T).
+```
+
+## Design
+
+All geometry for **authored** parts is computed analytically from the feature tree; bend axis, radius, and
+angle are known inputs recorded on each `BendFeature`, so the unfold reads the tree rather than
+reverse-engineering the B-rep. The **foreign-solid** path (`unfoldSolid`) is the exception: it detects bend
+geometry numerically from the public surface queries (no recorded tree). No kernel/WASM changes are required
+for either path.
+
+## Usage
+
+```ts
+import { MATERIALS, getMaterial } from 'brepjs-sheetmetal';
+
+const steel = getMaterial('steel-16ga');
+```
+
+All public operations return `Result<T>` (from `brepjs`); non-fatal warnings travel inside the `Ok` payload.
+
+## Snapshot harness
+
+A standalone visual harness lives in `harness/snapshot.ts`. It imports
+`brepjs-sheetmetal` directly (no playground dependency), builds a set of demos
+(the headline L-bracket with a mitered corner, a tray, reliefs, a cutout panel, a
+**tab-and-slot box** (self-locating corner joint), and a **louvered panel** (vent
+flaps + emboss/dimple)), then renders each folded 3D part next to its developed
+flat pattern as a single side-by-side SVG and also writes the folded solid as STEP.
+It also runs a **nesting** demo (a handful of parts bbox-packed onto one sheet),
+printing the sheet count + utilization and writing the nested sheet as DXF + SVG,
+plus an **nfp vs bbox** comparison nesting identical L-shaped parts with both
+strategies and printing the true-shape utilization gain.
+
+```bash
+npm run snapshot --workspace=brepjs-sheetmetal
+# writes harness/out/bracket.svg  (folded isometric wireframe + flat pattern)
+#        harness/out/bracket.step (folded solid)
+```
+
+The folded view is an isometric edge-wireframe projection of the kernel mesh, so
+the harness runs as a plain `tsx` script wherever the WASM kernel runs, with no
+headless browser or GPU required. Output lands in `harness/out/` (gitignored).
+
+## Development
+
+```bash
+npm run typecheck --workspace=brepjs-sheetmetal
+npm run lint --workspace=brepjs-sheetmetal
+npm run build --workspace=brepjs-sheetmetal
+npm run test --workspace=brepjs-sheetmetal
+npx tsc -p packages/brepjs-sheetmetal/harness/tsconfig.json   # typecheck the harness
+```

package/dist/allowanceFns.d.ts

@@ -0,0 +1,21 @@
+import { Result } from 'brepjs';
+import { BendRule, SheetMetalWarning } from './types.js';
+/**
+ * Bend allowance — the developed (flat) length of material consumed by a bend,
+ * measured along the neutral axis. Resolution precedence (see
+ * {@link resolveBendAllowance}): a referenced bend table, then an explicit
+ * `rule.allowance` override, then the K-factor formula
+ * BA = (π/180)·|angle|·(R + K·T). An optional `onWarning` receives the clamp
+ * warning when a table query falls outside its tabulated range.
+ */
+export declare function bendAllowance(angleDeg: number, thickness: number, rule: BendRule, onWarning?: (warning: SheetMetalWarning) => void): Result<number>;
+/**
+ * Developed length of the bend region when flattened — the neutral-axis arc
+ * length that replaces the curved patch in the flat pattern. Identical to the
+ * bend allowance (kept distinct in name for the unfold call sites that consume
+ * it as a strip width), and routed through the same {@link resolveBendAllowance}
+ * resolution (table → explicit allowance → K-factor).
+ */
+export declare function developedLength(angleDeg: number, thickness: number, rule: BendRule, onWarning?: (warning: SheetMetalWarning) => void): Result<number>;
+/** Neutral-axis radius R + K·T (the radius the developed arc length is measured at). */
+export declare function neutralRadius(thickness: number, rule: BendRule): Result<number>;