brepjs-sheetmetal 0.2.0 → 0.3.1

package/dist/brepjs-sheetmetal.cjs

@@ -505,7 +505,7 @@ function buildFeatureTree(graph, rootId = ROOT_FLAT_ID) {
 		adjacency.get(edge.parent)?.push(edge);
 		adjacency.get(edge.child)?.push(edge);
 	}
-	const visited = new Set([rootId]);
+	const visited = /* @__PURE__ */ new Set([rootId]);
 	const treeEdges = /* @__PURE__ */ new Set();
 	const bends = [];
 	const queue = [rootId];
@@ -674,18 +674,20 @@ function unfold(part) {
 		direction: p.direction,
 		inward: [-p.frame.v[0], -p.frame.v[1]]
 	})).concat(contourResult.value.bendLines).concat(hemJogResult.value.bendLines);
+	const pattern = {
+		outline: outlineResult.value,
+		bendLines,
+		holes: holesResult.value,
+		formCuts: formsResult.value.cuts,
+		formMarkers: formsResult.value.markers,
+		formHinges: formsResult.value.hinges,
+		loftedDevelopments: loftedResult.value,
+		developedArea: layout.developedArea
+	};
+	const report = reportFromLayout(layout);
 	return (0, brepjs.ok)({
-		pattern: {
-			outline: outlineResult.value,
-			bendLines,
-			holes: holesResult.value,
-			formCuts: formsResult.value.cuts,
-			formMarkers: formsResult.value.markers,
-			formHinges: formsResult.value.hinges,
-			loftedDevelopments: loftedResult.value,
-			developedArea: layout.developedArea
-		},
-		report: reportFromLayout(layout),
+		pattern,
+		report,
 		warnings
 	});
 }
@@ -1308,7 +1310,8 @@ function sampleFace(face, n) {
 	for (let i = 0; i < n; i += 1) {
 		const u = n === 1 ? .5 : i / (n - 1);
 		for (let j = 0; j < n; j += 1) {
-			const point = (0, brepjs.pointOnSurface)(face, u, n === 1 ? .5 : j / (n - 1));
+			const v = n === 1 ? .5 : j / (n - 1);
+			const point = (0, brepjs.pointOnSurface)(face, u, v);
 			const normal = (0, brepjs.normalAt)(face, point);
 			const len = (0, brepjs.vecLength)(normal);
 			if (len < GEOM_TOL) continue;
@@ -1399,7 +1402,7 @@ function axisFromNormals(normals) {
 }
 /** An orthonormal pair spanning the plane perpendicular to `axis`. */
 function perpBasis(axis) {
-	const e1 = (0, brepjs.vecNormalize)((0, brepjs.vecCross)(axis, Math.abs(axis[0]) < .9 ? [
+	const seed = Math.abs(axis[0]) < .9 ? [
 		1,
 		0,
 		0
@@ -1407,7 +1410,8 @@ function perpBasis(axis) {
 		0,
 		1,
 		0
-	]));
+	];
+	const e1 = (0, brepjs.vecNormalize)((0, brepjs.vecCross)(axis, seed));
 	return {
 		e1,
 		e2: (0, brepjs.vecNormalize)((0, brepjs.vecCross)(axis, e1))
@@ -1416,7 +1420,9 @@ function perpBasis(axis) {
 /** Perpendicular distance from `p` to the line through `o` with unit direction `d`. */
 function distanceToAxis(p, o, d) {
 	const w = (0, brepjs.vecSub)(p, o);
-	return (0, brepjs.vecLength)((0, brepjs.vecSub)(w, (0, brepjs.vecScale)(d, (0, brepjs.vecDot)(w, d))));
+	const along = (0, brepjs.vecDot)(w, d);
+	const perp = (0, brepjs.vecSub)(w, (0, brepjs.vecScale)(d, along));
+	return (0, brepjs.vecLength)(perp);
 }
 /** Algebraic (Kåsa) least-squares circle fit to 2D points. */
 function fitCircle2(pts) {
@@ -1621,7 +1627,8 @@ function detectThickness(planar) {
 		const fb = planar[j];
 		if (fa === void 0 || fb === void 0) continue;
 		const na = faceNormal(fa);
-		if ((0, brepjs.vecDot)(na, faceNormal(fb)) > -.99) continue;
+		const nb = faceNormal(fb);
+		if ((0, brepjs.vecDot)(na, nb) > -.99) continue;
 		const ca = (0, brepjs.faceCenter)(fa);
 		const cb = (0, brepjs.faceCenter)(fb);
 		const gap = Math.abs((0, brepjs.vecDot)((0, brepjs.vecSub)(cb, ca), na));
@@ -1650,7 +1657,8 @@ function pairFlats(planar, thickness, warnings) {
 			if (j === i || used.has(j)) continue;
 			const fb = planar[j];
 			if (fb === void 0) continue;
-			if ((0, brepjs.vecDot)(na, faceNormal(fb)) > -.99) continue;
+			const nb = faceNormal(fb);
+			if ((0, brepjs.vecDot)(na, nb) > -.99) continue;
 			const cb = (0, brepjs.faceCenter)(fb);
 			const gap = Math.abs((0, brepjs.vecDot)((0, brepjs.vecSub)(cb, ca), na));
 			const e = Math.abs(gap - thickness);
@@ -1819,7 +1827,7 @@ function layoutForeign(flats, graph, thickness, kFactor, warnings) {
 		adjacency.get(e.flats[0])?.push(e);
 		adjacency.get(e.flats[1])?.push(e);
 	}
-	const visited = new Set([0]);
+	const visited = /* @__PURE__ */ new Set([0]);
 	const treeEdges = /* @__PURE__ */ new Set();
 	const treeBends = [];
 	const queue = [0];
@@ -1913,23 +1921,26 @@ function layoutForeign(flats, graph, thickness, kFactor, warnings) {
 		});
 	}
 	const bbox = aabb2(rects);
-	const outlineWire = (0, brepjs.wireLoop)(buildRectOutline2(bbox));
+	const outline = buildRectOutline2(bbox);
+	const outlineWire = (0, brepjs.wireLoop)(outline);
 	if (!outlineWire.ok) return outlineWire;
+	const pattern = {
+		outline: outlineWire.value,
+		bendLines,
+		holes: [],
+		formCuts: [],
+		formMarkers: [],
+		formHinges: [],
+		loftedDevelopments: [],
+		developedArea
+	};
+	const report = {
+		bends: bendReportRows,
+		totalFlatSize: [bbox.x1 - bbox.x0, bbox.y1 - bbox.y0]
+	};
 	return (0, brepjs.ok)({
-		pattern: {
-			outline: outlineWire.value,
-			bendLines,
-			holes: [],
-			formCuts: [],
-			formMarkers: [],
-			formHinges: [],
-			loftedDevelopments: [],
-			developedArea
-		},
-		report: {
-			bends: bendReportRows,
-			totalFlatSize: [bbox.x1 - bbox.x0, bbox.y1 - bbox.y0]
-		}
+		pattern,
+		report
 	});
 }
 /** Map a 3D in-plane point through a placed flat's affine map. */
@@ -2019,7 +2030,9 @@ function parentFootprintCentreAlong(parent, axisInPlane, axisRef) {
 		min = Math.min(min, v);
 		max = Math.max(max, v);
 	}
-	return (0, brepjs.vecAdd)(axisRef, (0, brepjs.vecScale)(axisInPlane, (min + max) / 2 - (0, brepjs.vecDot)(axisRef, axisInPlane)));
+	const mid = (min + max) / 2;
+	const refAlong = (0, brepjs.vecDot)(axisRef, axisInPlane);
+	return (0, brepjs.vecAdd)(axisRef, (0, brepjs.vecScale)(axisInPlane, mid - refAlong));
 }
 /** In-plane run extent of a flat along `out` (perpendicular to the bend axis). */
 function inPlaneRun(flat, out) {
@@ -2035,7 +2048,8 @@ function inPlaneRun(flat, out) {
 }
 /** Run direction of a child flat pointing away from the bend axis. */
 function runDirectionAway(flat, out, axisOrigin) {
-	return (0, brepjs.vecDot)((0, brepjs.vecSub)(flat.center, axisOrigin), out) >= 0 ? out : (0, brepjs.vecScale)(out, -1);
+	const toCenter = (0, brepjs.vecSub)(flat.center, axisOrigin);
+	return (0, brepjs.vecDot)(toCenter, out) >= 0 ? out : (0, brepjs.vecScale)(out, -1);
 }
 /**
 * The child corner that develops onto the strip-far near point: minimum along the
@@ -2161,7 +2175,8 @@ function bendAxialExtent(bend) {
 * parent flat's mid-surface, 'down' otherwise.
 */
 function bendDirection(bend, parent) {
-	return (0, brepjs.vecDot)((0, brepjs.vecSub)(bend.fit.axisOrigin, parent.center), parent.normal) >= 0 ? "up" : "down";
+	const toAxis = (0, brepjs.vecSub)(bend.fit.axisOrigin, parent.center);
+	return (0, brepjs.vecDot)(toAxis, parent.normal) >= 0 ? "up" : "down";
 }
 function faceNormal(face) {
 	return (0, brepjs.vecNormalize)((0, brepjs.normalAt)(face, (0, brepjs.faceCenter)(face)));
@@ -2495,10 +2510,10 @@ function parentEdge(f, side) {
 			length = f.uLen;
 			a = o;
 			b = uTop;
-			break;
 	}
 	const dir = (0, brepjs.vecNormalize)((0, brepjs.vecCross)(f.n, out));
-	const start = (0, brepjs.vecDot)((0, brepjs.vecSub)(b, a), dir) >= 0 ? a : b;
+	const toB = (0, brepjs.vecSub)(b, a);
+	const start = (0, brepjs.vecDot)(toB, dir) >= 0 ? a : b;
 	return {
 		dir,
 		out,
@@ -2611,14 +2626,15 @@ function frameTransform$1(axisT, runT, nT, edgeStart, offset) {
 	const applyR = (v) => (0, brepjs.vecAdd)((0, brepjs.vecAdd)((0, brepjs.vecScale)(runT, v[0]), (0, brepjs.vecScale)(axisT, v[1])), (0, brepjs.vecScale)(nT, v[2]));
 	return {
 		solid: (s) => {
-			return (0, brepjs.translate)(aa.angleDeg === 0 ? s : (0, brepjs.rotate)(s, aa.angleDeg, {
+			const rotated = aa.angleDeg === 0 ? s : (0, brepjs.rotate)(s, aa.angleDeg, {
 				at: [
 					0,
 					0,
 					0
 				],
 				axis: aa.axis
-			}), target);
+			});
+			return (0, brepjs.translate)(rotated, target);
 		},
 		point: (p) => (0, brepjs.vecAdd)(applyR(p), target),
 		vector: applyR
@@ -2680,12 +2696,13 @@ function matrixToAxisAngle$2(m) {
 		};
 	}
 	const denom = 2 * Math.sin(angle);
+	const axis = [
+		(m21 - m12) / denom,
+		(m02 - m20) / denom,
+		(m10 - m01) / denom
+	];
 	return {
-		axis: (0, brepjs.vecNormalize)([
-			(m21 - m12) / denom,
-			(m02 - m20) / denom,
-			(m10 - m01) / denom
-		]),
+		axis: (0, brepjs.vecNormalize)(axis),
 		angleDeg
 	};
 }
@@ -2707,14 +2724,15 @@ function buildBendPatch$1(axisOrigin, thetaDeg, r, width, thickness, direction)
 	});
 	let tube = outer;
 	if (r > 1e-9) {
-		const carved = (0, brepjs.cut)(outer, (0, brepjs.cylinder)(r, width, {
+		const inner = (0, brepjs.cylinder)(r, width, {
 			at: axisOrigin,
 			axis: [
 				0,
 				1,
 				0
 			]
-		}));
+		});
+		const carved = (0, brepjs.cut)(outer, inner);
 		if (!carved.ok) return carved;
 		tube = carved.value;
 	}
@@ -2732,39 +2750,47 @@ function buildBendPatch$1(axisOrigin, thetaDeg, r, width, thickness, direction)
 function buildWedge$1(axisOrigin, thetaDeg, outerR, width, direction) {
 	const span = outerR * 2 + 2;
 	const margin = 1;
-	const halfA = (0, brepjs.translate)((0, brepjs.box)(span, width + 2 * margin, 2 * span), [
+	const blockA = (0, brepjs.box)(span, width + 2, 2 * span);
+	const halfA = (0, brepjs.translate)(blockA, [
 		axisOrigin[0],
 		axisOrigin[1] - margin,
 		axisOrigin[2] - span
 	]);
-	return (0, brepjs.intersect)(halfA, (0, brepjs.rotate)(halfA, (direction === "up" ? 1 : -1) * (180 - thetaDeg), {
+	const halfB = (0, brepjs.rotate)(halfA, (direction === "up" ? 1 : -1) * (180 - thetaDeg), {
 		at: axisOrigin,
 		axis: [
 			0,
 			1,
 			0
 		]
-	}));
+	});
+	return (0, brepjs.intersect)(halfA, halfB);
 }
 /** The flange flat, built lying along +X past the bend, then folded to angle θ. */
 function buildFlangeFlat(axisOrigin, thetaDeg, width, thickness, length, direction) {
-	if (direction === "up") return (0, brepjs.rotate)((0, brepjs.translate)((0, brepjs.box)(length, width, thickness), [
-		axisOrigin[0],
-		axisOrigin[1],
-		0
-	]), -thetaDeg, {
-		at: axisOrigin,
-		axis: [
-			0,
-			1,
+	if (direction === "up") {
+		const flat = (0, brepjs.box)(length, width, thickness);
+		const positioned = (0, brepjs.translate)(flat, [
+			axisOrigin[0],
+			axisOrigin[1],
 			0
-		]
-	});
-	return (0, brepjs.rotate)((0, brepjs.translate)((0, brepjs.box)(length, width, thickness), [
+		]);
+		return (0, brepjs.rotate)(positioned, -thetaDeg, {
+			at: axisOrigin,
+			axis: [
+				0,
+				1,
+				0
+			]
+		});
+	}
+	const flat = (0, brepjs.box)(length, width, thickness);
+	const positioned = (0, brepjs.translate)(flat, [
 		axisOrigin[0],
 		axisOrigin[1],
 		-thickness
-	]), thetaDeg, {
+	]);
+	return (0, brepjs.rotate)(positioned, thetaDeg, {
 		at: axisOrigin,
 		axis: [
 			0,
@@ -3048,7 +3074,8 @@ function cornerPoint$1(originA, dirA, originB, dirB) {
 	const e = (0, brepjs.vecDot)(dirB, w0);
 	const denom = a * c - b * b;
 	if (Math.abs(denom) < 1e-9) return originA;
-	return (0, brepjs.vecAdd)(originA, (0, brepjs.vecScale)(dirA, (b * e - c * d) / denom));
+	const sc = (b * e - c * d) / denom;
+	return (0, brepjs.vecAdd)(originA, (0, brepjs.vecScale)(dirA, sc));
 }
 /** In-plane perpendicular to `axis` pointing toward the part center (into the parent). */
 function inwardRun(axisOrigin, axis, center) {
@@ -3081,11 +3108,12 @@ function parentEdgeLength(part, flange) {
 */
 function slotTool3d(at, along, inward, width, depth, thickness) {
 	const margin = thickness + 2;
-	const y0 = (0, brepjs.vecDot)([
+	const rotPerp = [
 		-along[1],
 		along[0],
 		0
-	], inward) >= 0 ? 0 : -depth;
+	];
+	const y0 = (0, brepjs.vecDot)(rotPerp, inward) >= 0 ? 0 : -depth;
 	let tool = (0, brepjs.box)(width, depth, thickness + 2 * margin);
 	tool = (0, brepjs.translate)(tool, [
 		-width / 2,
@@ -3110,7 +3138,8 @@ function squareTool(solid, cornerXY, side) {
 	const b = (0, brepjs.getBounds)(solid);
 	const margin = 2;
 	const h = side / 2;
-	return (0, brepjs.translate)((0, brepjs.box)(side, side, b.zMax - b.zMin + 2 * margin), [
+	const tool = (0, brepjs.box)(side, side, b.zMax - b.zMin + 4);
+	return (0, brepjs.translate)(tool, [
 		cornerXY[0] - h,
 		cornerXY[1] - h,
 		b.zMin - margin
@@ -3603,18 +3632,20 @@ function embossForm(part, partSolid, spec, regionId, world, dev, ext) {
 	let solid;
 	if (spec.form === "emboss") {
 		const base = (0, brepjs.vecAdd)(faceCentre, (0, brepjs.vecScale)(world.n, -.05));
-		const fused = (0, brepjs.fuse)(partSolid, (0, brepjs.cylinder)(r, spec.height + HAIR, {
+		const bump = (0, brepjs.cylinder)(r, spec.height + HAIR, {
 			at: base,
 			axis: world.n
-		}));
+		});
+		const fused = (0, brepjs.fuse)(partSolid, bump);
 		if (!fused.ok) return fused;
 		solid = normalizeSolid(fused.value);
 	} else {
 		const top = (0, brepjs.vecAdd)(faceCentre, (0, brepjs.vecScale)(world.n, HAIR));
-		const cutResult = (0, brepjs.cut)(partSolid, (0, brepjs.cylinder)(r, spec.height + HAIR, {
+		const tool = (0, brepjs.cylinder)(r, spec.height + HAIR, {
 			at: top,
 			axis: (0, brepjs.vecScale)(world.n, -1)
-		}));
+		});
+		const cutResult = (0, brepjs.cut)(partSolid, tool);
 		if (!cutResult.ok) return cutResult;
 		solid = normalizeSolid(cutResult.value);
 	}
@@ -3706,7 +3737,8 @@ function buildLouverFlap(f, x0, x1, y0, width, height, thickness, sign) {
 	const n = (0, brepjs.vecNormalize)(f.n);
 	const v = (0, brepjs.vecNormalize)((0, brepjs.vecCross)(n, u));
 	const hingeCorner = (0, brepjs.vecAdd)((0, brepjs.vecAdd)((0, brepjs.vecAdd)(f.origin, (0, brepjs.vecScale)(f.u, x0)), (0, brepjs.vecScale)(f.v, y0)), (0, brepjs.vecScale)(f.n, thickness));
-	return (0, brepjs.ok)(mapLocalToWorld(flap, u, v, n, hingeCorner));
+	const placed = mapLocalToWorld(flap, u, v, n, hingeCorner);
+	return (0, brepjs.ok)(placed);
 }
 /** Map a solid built in a canonical XYZ frame onto world axes (uT, vT, nT) at origin. */
 function mapLocalToWorld(s, uT, vT, nT, origin) {
@@ -3721,14 +3753,15 @@ function mapLocalToWorld(s, uT, vT, nT, origin) {
 		vT[2],
 		nT[2]
 	]);
-	return (0, brepjs.translate)(aa.angleDeg === 0 ? s : (0, brepjs.rotate)(s, aa.angleDeg, {
+	const rotated = aa.angleDeg === 0 ? s : (0, brepjs.rotate)(s, aa.angleDeg, {
 		at: [
 			0,
 			0,
 			0
 		],
 		axis: aa.axis
-	}), origin);
+	});
+	return (0, brepjs.translate)(rotated, origin);
 }
 /** Axis-angle of a 3×3 row-major rotation matrix (columns = target basis). */
 function matrixToAxisAngle$1(m) {
@@ -3786,12 +3819,13 @@ function matrixToAxisAngle$1(m) {
 		};
 	}
 	const denom = 2 * Math.sin(angle);
+	const axis = [
+		(m21 - m12) / denom,
+		(m02 - m20) / denom,
+		(m10 - m01) / denom
+	];
 	return {
-		axis: (0, brepjs.vecNormalize)([
-			(m21 - m12) / denom,
-			(m02 - m20) / denom,
-			(m10 - m01) / denom
-		]),
+		axis: (0, brepjs.vecNormalize)(axis),
 		angleDeg
 	};
 }
@@ -4706,7 +4740,8 @@ function cornerPoint(originA, dirA, originB, dirB) {
 	const e = (0, brepjs.vecDot)(dirB, w0);
 	const denom = a * c - b * b;
 	if (Math.abs(denom) < 1e-9) return originA;
-	return (0, brepjs.vecAdd)(originA, (0, brepjs.vecScale)(dirA, (b * e - c * d) / denom));
+	const sc = (b * e - c * d) / denom;
+	return (0, brepjs.vecAdd)(originA, (0, brepjs.vecScale)(dirA, sc));
 }
 /**
 * Normal of the miter plane between two flanges whose bend axes are `dirA`/`dirB`.
@@ -4738,13 +4773,14 @@ function halfSpaceTool(solid, plane) {
 		-size / 2,
 		0
 	]);
-	return (0, brepjs.ok)((0, brepjs.translate)(alignZTo(tool, normal), plane.origin));
+	const aligned = alignZTo(tool, normal);
+	return (0, brepjs.ok)((0, brepjs.translate)(aligned, plane.origin));
 }
 /** Rotate a shape so its local +Z axis points along `target` (about the origin). */
 function alignZTo(shape, target) {
 	const dot = (0, brepjs.vecDot)(Z_AXIS, target);
-	if (dot > .999999999) return shape;
-	if (dot < -.999999999) return (0, brepjs.rotate)(shape, 180, {
+	if (dot > 1 - 1e-9) return shape;
+	if (dot < -1 + 1e-9) return (0, brepjs.rotate)(shape, 180, {
 		at: [
 			0,
 			0,
@@ -4757,7 +4793,8 @@ function alignZTo(shape, target) {
 		]
 	});
 	const axis = (0, brepjs.vecNormalize)((0, brepjs.vecCross)(Z_AXIS, target));
-	return (0, brepjs.rotate)(shape, Math.acos(Math.max(-1, Math.min(1, dot))) * 180 / Math.PI, {
+	const angleDeg = Math.acos(Math.max(-1, Math.min(1, dot))) * 180 / Math.PI;
+	return (0, brepjs.rotate)(shape, angleDeg, {
 		at: [
 			0,
 			0,
@@ -4888,7 +4925,8 @@ function authorContourFlange(part, spec) {
 function buildLineLeg(base, frame, span, thickness, legLength) {
 	const place = frameTransform(frame.run, frame.axis, frame.n, frame.origin);
 	const canon = (0, brepjs.box)(legLength, span, thickness);
-	const fused = (0, brepjs.fuse)(base, place.solid(canon));
+	const placed = place.solid(canon);
+	const fused = (0, brepjs.fuse)(base, placed);
 	if (!fused.ok) return fused;
 	const nextOrigin = (0, brepjs.vecAdd)(frame.origin, (0, brepjs.vecScale)(frame.run, legLength));
 	return (0, brepjs.ok)({
@@ -4920,7 +4958,8 @@ function buildArcBend(base, frame, span, thickness, seg) {
 	const place = frameTransform(frame.run, frame.axis, frame.n, frame.origin);
 	const patch = buildBendPatch(canonOrigin, seg.angleDeg, r, span, thickness, seg.direction);
 	if (!patch.ok) return patch;
-	const fused = (0, brepjs.fuse)(base, place.solid(patch.value));
+	const placed = place.solid(patch.value);
+	const fused = (0, brepjs.fuse)(base, placed);
 	if (!fused.ok) return fused;
 	const theta = seg.angleDeg * Math.PI / 180;
 	const a = -sign * theta;
@@ -4977,14 +5016,15 @@ function frameTransform(runT, axisT, nT, origin) {
 	const applyR = (v) => (0, brepjs.vecAdd)((0, brepjs.vecAdd)((0, brepjs.vecScale)(runT, v[0]), (0, brepjs.vecScale)(axisT, v[1])), (0, brepjs.vecScale)(nT, v[2]));
 	return {
 		solid: (s) => {
-			return (0, brepjs.translate)(aa.angleDeg === 0 ? s : (0, brepjs.rotate)(s, aa.angleDeg, {
+			const rotated = aa.angleDeg === 0 ? s : (0, brepjs.rotate)(s, aa.angleDeg, {
 				at: [
 					0,
 					0,
 					0
 				],
 				axis: aa.axis
-			}), origin);
+			});
+			return (0, brepjs.translate)(rotated, origin);
 		},
 		point: (p) => (0, brepjs.vecAdd)(applyR(p), origin),
 		vector: applyR
@@ -5045,10 +5085,10 @@ function baseEdge(part, side) {
 			length = uLen;
 			a = o;
 			b = uTop;
-			break;
 	}
 	const dir = (0, brepjs.vecNormalize)((0, brepjs.vecCross)(n, out));
-	const start = (0, brepjs.vecDot)((0, brepjs.vecSub)(b, a), dir) >= 0 ? a : b;
+	const toB = (0, brepjs.vecSub)(b, a);
+	const start = (0, brepjs.vecDot)(toB, dir) >= 0 ? a : b;
 	return {
 		dir,
 		out,
@@ -5095,10 +5135,10 @@ function regionEdge(frame, side) {
 			length = frame.uLen;
 			a = o;
 			b = uTop;
-			break;
 	}
 	const dir = (0, brepjs.vecNormalize)((0, brepjs.vecCross)(frame.n, out));
-	const start = (0, brepjs.vecDot)((0, brepjs.vecSub)(b, a), dir) >= 0 ? a : b;
+	const toB = (0, brepjs.vecSub)(b, a);
+	const start = (0, brepjs.vecDot)(toB, dir) >= 0 ? a : b;
 	return {
 		dir,
 		out,
@@ -5132,14 +5172,15 @@ function buildBendPatch(axisOrigin, thetaDeg, r, width, thickness, direction) {
 	});
 	let tube = outer;
 	if (r > 1e-9) {
-		const carved = (0, brepjs.cut)(outer, (0, brepjs.cylinder)(r, width, {
+		const inner = (0, brepjs.cylinder)(r, width, {
 			at: axisOrigin,
 			axis: [
 				0,
 				1,
 				0
 			]
-		}));
+		});
+		const carved = (0, brepjs.cut)(outer, inner);
 		if (!carved.ok) return carved;
 		tube = carved.value;
 	}
@@ -5150,19 +5191,21 @@ function buildBendPatch(axisOrigin, thetaDeg, r, width, thickness, direction) {
 function buildWedge(axisOrigin, thetaDeg, outerR, width, direction) {
 	const span = outerR * 2 + 2;
 	const margin = 1;
-	const halfA = (0, brepjs.translate)((0, brepjs.box)(span, width + 2 * margin, 2 * span), [
+	const blockA = (0, brepjs.box)(span, width + 2, 2 * span);
+	const halfA = (0, brepjs.translate)(blockA, [
 		axisOrigin[0],
 		axisOrigin[1] - margin,
 		axisOrigin[2] - span
 	]);
-	return (0, brepjs.intersect)(halfA, (0, brepjs.rotate)(halfA, (direction === "up" ? 1 : -1) * (180 - thetaDeg), {
+	const halfB = (0, brepjs.rotate)(halfA, (direction === "up" ? 1 : -1) * (180 - thetaDeg), {
 		at: axisOrigin,
 		axis: [
 			0,
 			1,
 			0
 		]
-	}));
+	});
+	return (0, brepjs.intersect)(halfA, halfB);
 }
 /** Axis-angle of a 3×3 rotation matrix (row-major). */
 function matrixToAxisAngle(m) {
@@ -5220,12 +5263,13 @@ function matrixToAxisAngle(m) {
 		};
 	}
 	const denom = 2 * Math.sin(angle);
+	const axis = [
+		(m21 - m12) / denom,
+		(m02 - m20) / denom,
+		(m10 - m01) / denom
+	];
 	return {
-		axis: (0, brepjs.vecNormalize)([
-			(m21 - m12) / denom,
-			(m02 - m20) / denom,
-			(m10 - m01) / denom
-		]),
+		axis: (0, brepjs.vecNormalize)(axis),
 		angleDeg
 	};
 }
@@ -5350,10 +5394,13 @@ function buildQuadPlate(id, a0, a1, b1, b0, thickness) {
 }
 /** A flat triangle (p0,p1,p2) extruded by `thickness` along its own normal. */
 function buildTrianglePlate(id, p0, p1, p2, thickness) {
+	const e0 = (0, brepjs.line)(p0, p1);
+	const e1 = (0, brepjs.line)(p1, p2);
+	const e2 = (0, brepjs.line)(p2, p0);
 	const loopResult = (0, brepjs.wireLoop)([
-		(0, brepjs.line)(p0, p1),
-		(0, brepjs.line)(p1, p2),
-		(0, brepjs.line)(p2, p0)
+		e0,
+		e1,
+		e2
 	]);
 	if (!loopResult.ok) return loopResult;
 	const loop = loopResult.value;
@@ -6136,6 +6183,30 @@ function wireToPolygon(outline) {
 	return (0, brepjs.ok)(poly);
 }
 /**
+* Read a wire as an OPEN polyline: every edge start plus the final edge's end,
+* so the last vertex of a non-closing path (a form cut) isn't dropped the way
+* {@link wireToPolygon} drops it for closed loops.
+*
+* Arc edges are linearised to their endpoints — the same assumption
+* {@link wireToPolygon} and the DXF writer make. Form cuts are straight-sided
+* today (louver/lance slits), so this is exact; a future curved form-feature cut
+* would render as straight chords in the overlay until arc tessellation is added.
+*/
+function wireToOpenPolyline(wire) {
+	const edges = (0, brepjs.getEdges)(wire);
+	if (edges.length === 0) return [];
+	const pts = edges.map((edge) => {
+		const p = (0, brepjs.curveStartPoint)(edge);
+		return [p[0], p[1]];
+	});
+	const lastEdge = edges[edges.length - 1];
+	if (lastEdge) {
+		const e = (0, brepjs.curveEndPoint)(lastEdge);
+		pts.push([e[0], e[1]]);
+	}
+	return pts;
+}
+/**
 * Reduce a {@link FlatPattern} to serializable 2D polylines (outline, holes, bend
 * lines) for a developed-pattern overlay. Best-effort: a wire that fails to read
 * is dropped rather than throwing, so a partial pattern still yields what it can.
@@ -6161,6 +6232,15 @@ function flatPatternToPolylines(pattern) {
 				to: [end[0], end[1]],
 				direction: bend.direction
 			};
+		}),
+		formCuts: pattern.formCuts.map(wireToOpenPolyline).filter((p) => p.length >= 2),
+		formHinges: pattern.formHinges.map((hinge) => {
+			const start = (0, brepjs.curveStartPoint)(hinge);
+			const end = (0, brepjs.curveEndPoint)(hinge);
+			return {
+				from: [start[0], start[1]],
+				to: [end[0], end[1]]
+			};
 		})
 	};
 }

package/dist/brepjs-sheetmetal.js

@@ -504,7 +504,7 @@ function buildFeatureTree(graph, rootId = ROOT_FLAT_ID) {
 		adjacency.get(edge.parent)?.push(edge);
 		adjacency.get(edge.child)?.push(edge);
 	}
-	const visited = new Set([rootId]);
+	const visited = /* @__PURE__ */ new Set([rootId]);
 	const treeEdges = /* @__PURE__ */ new Set();
 	const bends = [];
 	const queue = [rootId];
@@ -673,18 +673,20 @@ function unfold(part) {
 		direction: p.direction,
 		inward: [-p.frame.v[0], -p.frame.v[1]]
 	})).concat(contourResult.value.bendLines).concat(hemJogResult.value.bendLines);
+	const pattern = {
+		outline: outlineResult.value,
+		bendLines,
+		holes: holesResult.value,
+		formCuts: formsResult.value.cuts,
+		formMarkers: formsResult.value.markers,
+		formHinges: formsResult.value.hinges,
+		loftedDevelopments: loftedResult.value,
+		developedArea: layout.developedArea
+	};
+	const report = reportFromLayout(layout);
 	return ok({
-		pattern: {
-			outline: outlineResult.value,
-			bendLines,
-			holes: holesResult.value,
-			formCuts: formsResult.value.cuts,
-			formMarkers: formsResult.value.markers,
-			formHinges: formsResult.value.hinges,
-			loftedDevelopments: loftedResult.value,
-			developedArea: layout.developedArea
-		},
-		report: reportFromLayout(layout),
+		pattern,
+		report,
 		warnings
 	});
 }
@@ -1307,7 +1309,8 @@ function sampleFace(face, n) {
 	for (let i = 0; i < n; i += 1) {
 		const u = n === 1 ? .5 : i / (n - 1);
 		for (let j = 0; j < n; j += 1) {
-			const point = pointOnSurface(face, u, n === 1 ? .5 : j / (n - 1));
+			const v = n === 1 ? .5 : j / (n - 1);
+			const point = pointOnSurface(face, u, v);
 			const normal = normalAt(face, point);
 			const len = vecLength(normal);
 			if (len < GEOM_TOL) continue;
@@ -1398,7 +1401,7 @@ function axisFromNormals(normals) {
 }
 /** An orthonormal pair spanning the plane perpendicular to `axis`. */
 function perpBasis(axis) {
-	const e1 = vecNormalize(vecCross(axis, Math.abs(axis[0]) < .9 ? [
+	const seed = Math.abs(axis[0]) < .9 ? [
 		1,
 		0,
 		0
@@ -1406,7 +1409,8 @@ function perpBasis(axis) {
 		0,
 		1,
 		0
-	]));
+	];
+	const e1 = vecNormalize(vecCross(axis, seed));
 	return {
 		e1,
 		e2: vecNormalize(vecCross(axis, e1))
@@ -1415,7 +1419,9 @@ function perpBasis(axis) {
 /** Perpendicular distance from `p` to the line through `o` with unit direction `d`. */
 function distanceToAxis(p, o, d) {
 	const w = vecSub(p, o);
-	return vecLength(vecSub(w, vecScale(d, vecDot(w, d))));
+	const along = vecDot(w, d);
+	const perp = vecSub(w, vecScale(d, along));
+	return vecLength(perp);
 }
 /** Algebraic (Kåsa) least-squares circle fit to 2D points. */
 function fitCircle2(pts) {
@@ -1620,7 +1626,8 @@ function detectThickness(planar) {
 		const fb = planar[j];
 		if (fa === void 0 || fb === void 0) continue;
 		const na = faceNormal(fa);
-		if (vecDot(na, faceNormal(fb)) > -.99) continue;
+		const nb = faceNormal(fb);
+		if (vecDot(na, nb) > -.99) continue;
 		const ca = faceCenter(fa);
 		const cb = faceCenter(fb);
 		const gap = Math.abs(vecDot(vecSub(cb, ca), na));
@@ -1649,7 +1656,8 @@ function pairFlats(planar, thickness, warnings) {
 			if (j === i || used.has(j)) continue;
 			const fb = planar[j];
 			if (fb === void 0) continue;
-			if (vecDot(na, faceNormal(fb)) > -.99) continue;
+			const nb = faceNormal(fb);
+			if (vecDot(na, nb) > -.99) continue;
 			const cb = faceCenter(fb);
 			const gap = Math.abs(vecDot(vecSub(cb, ca), na));
 			const e = Math.abs(gap - thickness);
@@ -1818,7 +1826,7 @@ function layoutForeign(flats, graph, thickness, kFactor, warnings) {
 		adjacency.get(e.flats[0])?.push(e);
 		adjacency.get(e.flats[1])?.push(e);
 	}
-	const visited = new Set([0]);
+	const visited = /* @__PURE__ */ new Set([0]);
 	const treeEdges = /* @__PURE__ */ new Set();
 	const treeBends = [];
 	const queue = [0];
@@ -1912,23 +1920,26 @@ function layoutForeign(flats, graph, thickness, kFactor, warnings) {
 		});
 	}
 	const bbox = aabb2(rects);
-	const outlineWire = wireLoop(buildRectOutline2(bbox));
+	const outline = buildRectOutline2(bbox);
+	const outlineWire = wireLoop(outline);
 	if (!outlineWire.ok) return outlineWire;
+	const pattern = {
+		outline: outlineWire.value,
+		bendLines,
+		holes: [],
+		formCuts: [],
+		formMarkers: [],
+		formHinges: [],
+		loftedDevelopments: [],
+		developedArea
+	};
+	const report = {
+		bends: bendReportRows,
+		totalFlatSize: [bbox.x1 - bbox.x0, bbox.y1 - bbox.y0]
+	};
 	return ok({
-		pattern: {
-			outline: outlineWire.value,
-			bendLines,
-			holes: [],
-			formCuts: [],
-			formMarkers: [],
-			formHinges: [],
-			loftedDevelopments: [],
-			developedArea
-		},
-		report: {
-			bends: bendReportRows,
-			totalFlatSize: [bbox.x1 - bbox.x0, bbox.y1 - bbox.y0]
-		}
+		pattern,
+		report
 	});
 }
 /** Map a 3D in-plane point through a placed flat's affine map. */
@@ -2018,7 +2029,9 @@ function parentFootprintCentreAlong(parent, axisInPlane, axisRef) {
 		min = Math.min(min, v);
 		max = Math.max(max, v);
 	}
-	return vecAdd(axisRef, vecScale(axisInPlane, (min + max) / 2 - vecDot(axisRef, axisInPlane)));
+	const mid = (min + max) / 2;
+	const refAlong = vecDot(axisRef, axisInPlane);
+	return vecAdd(axisRef, vecScale(axisInPlane, mid - refAlong));
 }
 /** In-plane run extent of a flat along `out` (perpendicular to the bend axis). */
 function inPlaneRun(flat, out) {
@@ -2034,7 +2047,8 @@ function inPlaneRun(flat, out) {
 }
 /** Run direction of a child flat pointing away from the bend axis. */
 function runDirectionAway(flat, out, axisOrigin) {
-	return vecDot(vecSub(flat.center, axisOrigin), out) >= 0 ? out : vecScale(out, -1);
+	const toCenter = vecSub(flat.center, axisOrigin);
+	return vecDot(toCenter, out) >= 0 ? out : vecScale(out, -1);
 }
 /**
 * The child corner that develops onto the strip-far near point: minimum along the
@@ -2160,7 +2174,8 @@ function bendAxialExtent(bend) {
 * parent flat's mid-surface, 'down' otherwise.
 */
 function bendDirection(bend, parent) {
-	return vecDot(vecSub(bend.fit.axisOrigin, parent.center), parent.normal) >= 0 ? "up" : "down";
+	const toAxis = vecSub(bend.fit.axisOrigin, parent.center);
+	return vecDot(toAxis, parent.normal) >= 0 ? "up" : "down";
 }
 function faceNormal(face) {
 	return vecNormalize(normalAt(face, faceCenter(face)));
@@ -2494,10 +2509,10 @@ function parentEdge(f, side) {
 			length = f.uLen;
 			a = o;
 			b = uTop;
-			break;
 	}
 	const dir = vecNormalize(vecCross(f.n, out));
-	const start = vecDot(vecSub(b, a), dir) >= 0 ? a : b;
+	const toB = vecSub(b, a);
+	const start = vecDot(toB, dir) >= 0 ? a : b;
 	return {
 		dir,
 		out,
@@ -2610,14 +2625,15 @@ function frameTransform$1(axisT, runT, nT, edgeStart, offset) {
 	const applyR = (v) => vecAdd(vecAdd(vecScale(runT, v[0]), vecScale(axisT, v[1])), vecScale(nT, v[2]));
 	return {
 		solid: (s) => {
-			return translate(aa.angleDeg === 0 ? s : rotate(s, aa.angleDeg, {
+			const rotated = aa.angleDeg === 0 ? s : rotate(s, aa.angleDeg, {
 				at: [
 					0,
 					0,
 					0
 				],
 				axis: aa.axis
-			}), target);
+			});
+			return translate(rotated, target);
 		},
 		point: (p) => vecAdd(applyR(p), target),
 		vector: applyR
@@ -2679,12 +2695,13 @@ function matrixToAxisAngle$2(m) {
 		};
 	}
 	const denom = 2 * Math.sin(angle);
+	const axis = [
+		(m21 - m12) / denom,
+		(m02 - m20) / denom,
+		(m10 - m01) / denom
+	];
 	return {
-		axis: vecNormalize([
-			(m21 - m12) / denom,
-			(m02 - m20) / denom,
-			(m10 - m01) / denom
-		]),
+		axis: vecNormalize(axis),
 		angleDeg
 	};
 }
@@ -2706,14 +2723,15 @@ function buildBendPatch$1(axisOrigin, thetaDeg, r, width, thickness, direction)
 	});
 	let tube = outer;
 	if (r > 1e-9) {
-		const carved = cut(outer, cylinder(r, width, {
+		const inner = cylinder(r, width, {
 			at: axisOrigin,
 			axis: [
 				0,
 				1,
 				0
 			]
-		}));
+		});
+		const carved = cut(outer, inner);
 		if (!carved.ok) return carved;
 		tube = carved.value;
 	}
@@ -2731,39 +2749,47 @@ function buildBendPatch$1(axisOrigin, thetaDeg, r, width, thickness, direction)
 function buildWedge$1(axisOrigin, thetaDeg, outerR, width, direction) {
 	const span = outerR * 2 + 2;
 	const margin = 1;
-	const halfA = translate(box(span, width + 2 * margin, 2 * span), [
+	const blockA = box(span, width + 2, 2 * span);
+	const halfA = translate(blockA, [
 		axisOrigin[0],
 		axisOrigin[1] - margin,
 		axisOrigin[2] - span
 	]);
-	return intersect(halfA, rotate(halfA, (direction === "up" ? 1 : -1) * (180 - thetaDeg), {
+	const halfB = rotate(halfA, (direction === "up" ? 1 : -1) * (180 - thetaDeg), {
 		at: axisOrigin,
 		axis: [
 			0,
 			1,
 			0
 		]
-	}));
+	});
+	return intersect(halfA, halfB);
 }
 /** The flange flat, built lying along +X past the bend, then folded to angle θ. */
 function buildFlangeFlat(axisOrigin, thetaDeg, width, thickness, length, direction) {
-	if (direction === "up") return rotate(translate(box(length, width, thickness), [
-		axisOrigin[0],
-		axisOrigin[1],
-		0
-	]), -thetaDeg, {
-		at: axisOrigin,
-		axis: [
-			0,
-			1,
+	if (direction === "up") {
+		const flat = box(length, width, thickness);
+		const positioned = translate(flat, [
+			axisOrigin[0],
+			axisOrigin[1],
 			0
-		]
-	});
-	return rotate(translate(box(length, width, thickness), [
+		]);
+		return rotate(positioned, -thetaDeg, {
+			at: axisOrigin,
+			axis: [
+				0,
+				1,
+				0
+			]
+		});
+	}
+	const flat = box(length, width, thickness);
+	const positioned = translate(flat, [
 		axisOrigin[0],
 		axisOrigin[1],
 		-thickness
-	]), thetaDeg, {
+	]);
+	return rotate(positioned, thetaDeg, {
 		at: axisOrigin,
 		axis: [
 			0,
@@ -3047,7 +3073,8 @@ function cornerPoint$1(originA, dirA, originB, dirB) {
 	const e = vecDot(dirB, w0);
 	const denom = a * c - b * b;
 	if (Math.abs(denom) < 1e-9) return originA;
-	return vecAdd(originA, vecScale(dirA, (b * e - c * d) / denom));
+	const sc = (b * e - c * d) / denom;
+	return vecAdd(originA, vecScale(dirA, sc));
 }
 /** In-plane perpendicular to `axis` pointing toward the part center (into the parent). */
 function inwardRun(axisOrigin, axis, center) {
@@ -3080,11 +3107,12 @@ function parentEdgeLength(part, flange) {
 */
 function slotTool3d(at, along, inward, width, depth, thickness) {
 	const margin = thickness + 2;
-	const y0 = vecDot([
+	const rotPerp = [
 		-along[1],
 		along[0],
 		0
-	], inward) >= 0 ? 0 : -depth;
+	];
+	const y0 = vecDot(rotPerp, inward) >= 0 ? 0 : -depth;
 	let tool = box(width, depth, thickness + 2 * margin);
 	tool = translate(tool, [
 		-width / 2,
@@ -3109,7 +3137,8 @@ function squareTool(solid, cornerXY, side) {
 	const b = getBounds(solid);
 	const margin = 2;
 	const h = side / 2;
-	return translate(box(side, side, b.zMax - b.zMin + 2 * margin), [
+	const tool = box(side, side, b.zMax - b.zMin + 4);
+	return translate(tool, [
 		cornerXY[0] - h,
 		cornerXY[1] - h,
 		b.zMin - margin
@@ -3602,18 +3631,20 @@ function embossForm(part, partSolid, spec, regionId, world, dev, ext) {
 	let solid;
 	if (spec.form === "emboss") {
 		const base = vecAdd(faceCentre, vecScale(world.n, -.05));
-		const fused = fuse(partSolid, cylinder(r, spec.height + HAIR, {
+		const bump = cylinder(r, spec.height + HAIR, {
 			at: base,
 			axis: world.n
-		}));
+		});
+		const fused = fuse(partSolid, bump);
 		if (!fused.ok) return fused;
 		solid = normalizeSolid(fused.value);
 	} else {
 		const top = vecAdd(faceCentre, vecScale(world.n, HAIR));
-		const cutResult = cut(partSolid, cylinder(r, spec.height + HAIR, {
+		const tool = cylinder(r, spec.height + HAIR, {
 			at: top,
 			axis: vecScale(world.n, -1)
-		}));
+		});
+		const cutResult = cut(partSolid, tool);
 		if (!cutResult.ok) return cutResult;
 		solid = normalizeSolid(cutResult.value);
 	}
@@ -3705,7 +3736,8 @@ function buildLouverFlap(f, x0, x1, y0, width, height, thickness, sign) {
 	const n = vecNormalize(f.n);
 	const v = vecNormalize(vecCross(n, u));
 	const hingeCorner = vecAdd(vecAdd(vecAdd(f.origin, vecScale(f.u, x0)), vecScale(f.v, y0)), vecScale(f.n, thickness));
-	return ok(mapLocalToWorld(flap, u, v, n, hingeCorner));
+	const placed = mapLocalToWorld(flap, u, v, n, hingeCorner);
+	return ok(placed);
 }
 /** Map a solid built in a canonical XYZ frame onto world axes (uT, vT, nT) at origin. */
 function mapLocalToWorld(s, uT, vT, nT, origin) {
@@ -3720,14 +3752,15 @@ function mapLocalToWorld(s, uT, vT, nT, origin) {
 		vT[2],
 		nT[2]
 	]);
-	return translate(aa.angleDeg === 0 ? s : rotate(s, aa.angleDeg, {
+	const rotated = aa.angleDeg === 0 ? s : rotate(s, aa.angleDeg, {
 		at: [
 			0,
 			0,
 			0
 		],
 		axis: aa.axis
-	}), origin);
+	});
+	return translate(rotated, origin);
 }
 /** Axis-angle of a 3×3 row-major rotation matrix (columns = target basis). */
 function matrixToAxisAngle$1(m) {
@@ -3785,12 +3818,13 @@ function matrixToAxisAngle$1(m) {
 		};
 	}
 	const denom = 2 * Math.sin(angle);
+	const axis = [
+		(m21 - m12) / denom,
+		(m02 - m20) / denom,
+		(m10 - m01) / denom
+	];
 	return {
-		axis: vecNormalize([
-			(m21 - m12) / denom,
-			(m02 - m20) / denom,
-			(m10 - m01) / denom
-		]),
+		axis: vecNormalize(axis),
 		angleDeg
 	};
 }
@@ -4705,7 +4739,8 @@ function cornerPoint(originA, dirA, originB, dirB) {
 	const e = vecDot(dirB, w0);
 	const denom = a * c - b * b;
 	if (Math.abs(denom) < 1e-9) return originA;
-	return vecAdd(originA, vecScale(dirA, (b * e - c * d) / denom));
+	const sc = (b * e - c * d) / denom;
+	return vecAdd(originA, vecScale(dirA, sc));
 }
 /**
 * Normal of the miter plane between two flanges whose bend axes are `dirA`/`dirB`.
@@ -4737,13 +4772,14 @@ function halfSpaceTool(solid, plane) {
 		-size / 2,
 		0
 	]);
-	return ok(translate(alignZTo(tool, normal), plane.origin));
+	const aligned = alignZTo(tool, normal);
+	return ok(translate(aligned, plane.origin));
 }
 /** Rotate a shape so its local +Z axis points along `target` (about the origin). */
 function alignZTo(shape, target) {
 	const dot = vecDot(Z_AXIS, target);
-	if (dot > .999999999) return shape;
-	if (dot < -.999999999) return rotate(shape, 180, {
+	if (dot > 1 - 1e-9) return shape;
+	if (dot < -1 + 1e-9) return rotate(shape, 180, {
 		at: [
 			0,
 			0,
@@ -4756,7 +4792,8 @@ function alignZTo(shape, target) {
 		]
 	});
 	const axis = vecNormalize(vecCross(Z_AXIS, target));
-	return rotate(shape, Math.acos(Math.max(-1, Math.min(1, dot))) * 180 / Math.PI, {
+	const angleDeg = Math.acos(Math.max(-1, Math.min(1, dot))) * 180 / Math.PI;
+	return rotate(shape, angleDeg, {
 		at: [
 			0,
 			0,
@@ -4887,7 +4924,8 @@ function authorContourFlange(part, spec) {
 function buildLineLeg(base, frame, span, thickness, legLength) {
 	const place = frameTransform(frame.run, frame.axis, frame.n, frame.origin);
 	const canon = box(legLength, span, thickness);
-	const fused = fuse(base, place.solid(canon));
+	const placed = place.solid(canon);
+	const fused = fuse(base, placed);
 	if (!fused.ok) return fused;
 	const nextOrigin = vecAdd(frame.origin, vecScale(frame.run, legLength));
 	return ok({
@@ -4919,7 +4957,8 @@ function buildArcBend(base, frame, span, thickness, seg) {
 	const place = frameTransform(frame.run, frame.axis, frame.n, frame.origin);
 	const patch = buildBendPatch(canonOrigin, seg.angleDeg, r, span, thickness, seg.direction);
 	if (!patch.ok) return patch;
-	const fused = fuse(base, place.solid(patch.value));
+	const placed = place.solid(patch.value);
+	const fused = fuse(base, placed);
 	if (!fused.ok) return fused;
 	const theta = seg.angleDeg * Math.PI / 180;
 	const a = -sign * theta;
@@ -4976,14 +5015,15 @@ function frameTransform(runT, axisT, nT, origin) {
 	const applyR = (v) => vecAdd(vecAdd(vecScale(runT, v[0]), vecScale(axisT, v[1])), vecScale(nT, v[2]));
 	return {
 		solid: (s) => {
-			return translate(aa.angleDeg === 0 ? s : rotate(s, aa.angleDeg, {
+			const rotated = aa.angleDeg === 0 ? s : rotate(s, aa.angleDeg, {
 				at: [
 					0,
 					0,
 					0
 				],
 				axis: aa.axis
-			}), origin);
+			});
+			return translate(rotated, origin);
 		},
 		point: (p) => vecAdd(applyR(p), origin),
 		vector: applyR
@@ -5044,10 +5084,10 @@ function baseEdge(part, side) {
 			length = uLen;
 			a = o;
 			b = uTop;
-			break;
 	}
 	const dir = vecNormalize(vecCross(n, out));
-	const start = vecDot(vecSub(b, a), dir) >= 0 ? a : b;
+	const toB = vecSub(b, a);
+	const start = vecDot(toB, dir) >= 0 ? a : b;
 	return {
 		dir,
 		out,
@@ -5094,10 +5134,10 @@ function regionEdge(frame, side) {
 			length = frame.uLen;
 			a = o;
 			b = uTop;
-			break;
 	}
 	const dir = vecNormalize(vecCross(frame.n, out));
-	const start = vecDot(vecSub(b, a), dir) >= 0 ? a : b;
+	const toB = vecSub(b, a);
+	const start = vecDot(toB, dir) >= 0 ? a : b;
 	return {
 		dir,
 		out,
@@ -5131,14 +5171,15 @@ function buildBendPatch(axisOrigin, thetaDeg, r, width, thickness, direction) {
 	});
 	let tube = outer;
 	if (r > 1e-9) {
-		const carved = cut(outer, cylinder(r, width, {
+		const inner = cylinder(r, width, {
 			at: axisOrigin,
 			axis: [
 				0,
 				1,
 				0
 			]
-		}));
+		});
+		const carved = cut(outer, inner);
 		if (!carved.ok) return carved;
 		tube = carved.value;
 	}
@@ -5149,19 +5190,21 @@ function buildBendPatch(axisOrigin, thetaDeg, r, width, thickness, direction) {
 function buildWedge(axisOrigin, thetaDeg, outerR, width, direction) {
 	const span = outerR * 2 + 2;
 	const margin = 1;
-	const halfA = translate(box(span, width + 2 * margin, 2 * span), [
+	const blockA = box(span, width + 2, 2 * span);
+	const halfA = translate(blockA, [
 		axisOrigin[0],
 		axisOrigin[1] - margin,
 		axisOrigin[2] - span
 	]);
-	return intersect(halfA, rotate(halfA, (direction === "up" ? 1 : -1) * (180 - thetaDeg), {
+	const halfB = rotate(halfA, (direction === "up" ? 1 : -1) * (180 - thetaDeg), {
 		at: axisOrigin,
 		axis: [
 			0,
 			1,
 			0
 		]
-	}));
+	});
+	return intersect(halfA, halfB);
 }
 /** Axis-angle of a 3×3 rotation matrix (row-major). */
 function matrixToAxisAngle(m) {
@@ -5219,12 +5262,13 @@ function matrixToAxisAngle(m) {
 		};
 	}
 	const denom = 2 * Math.sin(angle);
+	const axis = [
+		(m21 - m12) / denom,
+		(m02 - m20) / denom,
+		(m10 - m01) / denom
+	];
 	return {
-		axis: vecNormalize([
-			(m21 - m12) / denom,
-			(m02 - m20) / denom,
-			(m10 - m01) / denom
-		]),
+		axis: vecNormalize(axis),
 		angleDeg
 	};
 }
@@ -5349,10 +5393,13 @@ function buildQuadPlate(id, a0, a1, b1, b0, thickness) {
 }
 /** A flat triangle (p0,p1,p2) extruded by `thickness` along its own normal. */
 function buildTrianglePlate(id, p0, p1, p2, thickness) {
+	const e0 = line(p0, p1);
+	const e1 = line(p1, p2);
+	const e2 = line(p2, p0);
 	const loopResult = wireLoop([
-		line(p0, p1),
-		line(p1, p2),
-		line(p2, p0)
+		e0,
+		e1,
+		e2
 	]);
 	if (!loopResult.ok) return loopResult;
 	const loop = loopResult.value;
@@ -6135,6 +6182,30 @@ function wireToPolygon(outline) {
 	return ok(poly);
 }
 /**
+* Read a wire as an OPEN polyline: every edge start plus the final edge's end,
+* so the last vertex of a non-closing path (a form cut) isn't dropped the way
+* {@link wireToPolygon} drops it for closed loops.
+*
+* Arc edges are linearised to their endpoints — the same assumption
+* {@link wireToPolygon} and the DXF writer make. Form cuts are straight-sided
+* today (louver/lance slits), so this is exact; a future curved form-feature cut
+* would render as straight chords in the overlay until arc tessellation is added.
+*/
+function wireToOpenPolyline(wire) {
+	const edges = getEdges(wire);
+	if (edges.length === 0) return [];
+	const pts = edges.map((edge) => {
+		const p = curveStartPoint(edge);
+		return [p[0], p[1]];
+	});
+	const lastEdge = edges[edges.length - 1];
+	if (lastEdge) {
+		const e = curveEndPoint(lastEdge);
+		pts.push([e[0], e[1]]);
+	}
+	return pts;
+}
+/**
 * Reduce a {@link FlatPattern} to serializable 2D polylines (outline, holes, bend
 * lines) for a developed-pattern overlay. Best-effort: a wire that fails to read
 * is dropped rather than throwing, so a partial pattern still yields what it can.
@@ -6160,6 +6231,15 @@ function flatPatternToPolylines(pattern) {
 				to: [end[0], end[1]],
 				direction: bend.direction
 			};
+		}),
+		formCuts: pattern.formCuts.map(wireToOpenPolyline).filter((p) => p.length >= 2),
+		formHinges: pattern.formHinges.map((hinge) => {
+			const start = curveStartPoint(hinge);
+			const end = curveEndPoint(hinge);
+			return {
+				from: [start[0], start[1]],
+				to: [end[0], end[1]]
+			};
 		})
 	};
 }

package/dist/polygonFns.d.ts

@@ -24,6 +24,13 @@ export interface FlatPatternPolylines {
     holes: Polygon[];
     /** Bend lines, each with its fold direction. */
     bendLines: FlatPatternBendLine[];
+    /** Open form-feature cut paths in the blank (e.g. louver/lance three-sided cuts). */
+    formCuts: Polygon[];
+    /** Form-feature hinge lines (the uncut fold edge a louver/lance forms up along). */
+    formHinges: {
+        from: Pt2;
+        to: Pt2;
+    }[];
 }
 /**
  * Reduce a {@link FlatPattern} to serializable 2D polylines (outline, holes, bend

package/package.json

@@ -1,6 +1,6 @@
 {
   "name": "brepjs-sheetmetal",
-  "version": "0.2.0",
+  "version": "0.3.1",
   "description": "Sheet-metal CAD domain for brepjs — flange authoring, auto-miter, fold/unfold flat patterns",
   "keywords": [
     "sheet-metal",
@@ -43,7 +43,7 @@
   ],
   "scripts": {
     "build": "vite build",
-    "typecheck": "tsc --noEmit",
+    "typecheck": "tsgo --noEmit",
     "test": "vitest run",
     "snapshot": "tsx harness/snapshot.ts",
     "lint": "eslint src tests"
@@ -53,10 +53,9 @@
   },
   "devDependencies": {
     "@eslint/js": "*",
-    "@types/node": "25.9.2",
-    "brepjs-opencascade": ">=0.16.0",
+    "@types/node": "26.2.0",
     "eslint": "*",
-    "tsx": "4.22.4",
+    "tsx": "4.23.11",
     "typescript": "*",
     "typescript-eslint": "*",
     "vite": "^8.0.0",