brepjs-sheetmetal 0.4.0 → 0.4.1

package/README.md

@@ -300,7 +300,10 @@ authored path. It reads only the B-rep:
   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.
+  mid-surface flat. Two antiparallel faces count as opposed only when they face each other (an interior
+  point of one projects inside the other), so a flange's end cap and the adjacent flange's inner face, a
+  bend radius apart across a corner, never pair. 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
@@ -320,8 +323,9 @@ non-uniform thickness, conical/spline bend faces, non-manifold / non-sheet topol
 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.
+authored unfold's developed area, bend count, flat count, and total flat bbox with no warnings (single bend,
+plus the L-bracket, U-channel, and four-sided tray at thicknesses 1, 1.5, 2, and 3 against a 2 mm inner
+radius), reading only the solid, never the feature tree.
 
 ## Bend tables
 

package/dist/brepjs-sheetmetal.cjs

@@ -1286,6 +1286,61 @@ function reportFromLayout(layout) {
 		totalFlatSize: [maxX - minX, maxY - minY]
 	};
 }
+// \0@oxc-project+runtime@0.155.0/helpers/esm/usingCtx.js
+function _usingCtx() {
+	var r = "function" == typeof SuppressedError ? SuppressedError : function(r, e) {
+		var n = Error();
+		return n.name = "SuppressedError", n.error = r, n.suppressed = e, n;
+	}, e = {}, n = [];
+	function using(r, e) {
+		if (null != e) {
+			if (Object(e) !== e) throw new TypeError("using declarations can only be used with objects, functions, null, or undefined.");
+			if (r) var o = e[Symbol.asyncDispose || Symbol["for"]("Symbol.asyncDispose")];
+			if (void 0 === o && (o = e[Symbol.dispose || Symbol["for"]("Symbol.dispose")], r)) var t = o;
+			if ("function" != typeof o) throw new TypeError("Object is not disposable.");
+			t && (o = function o() {
+				try {
+					t.call(e);
+				} catch (r) {
+					return Promise.reject(r);
+				}
+			}), n.push({
+				v: e,
+				d: o,
+				a: r
+			});
+		} else r && n.push({
+			d: e,
+			a: r
+		});
+		return e;
+	}
+	return {
+		e,
+		u: using.bind(null, !1),
+		a: using.bind(null, !0),
+		d: function d() {
+			var o, t = this.e, s = 0;
+			function next() {
+				for (; o = n.pop();) try {
+					if (!o.a && 1 === s) return s = 0, n.push(o), Promise.resolve().then(next);
+					if (o.d) {
+						var r = o.d.call(o.v);
+						if (o.a) return s |= 2, Promise.resolve(r).then(next, err);
+					} else s |= 1;
+				} catch (r) {
+					return err(r);
+				}
+				if (1 === s) return t !== e ? Promise.reject(t) : Promise.resolve();
+				if (t !== e) throw t;
+			}
+			function err(n) {
+				return t = t !== e ? new r(n, t) : n, next();
+			}
+			return next();
+		}
+	};
+}
 // src/foreignUnfoldFns.ts
 /** Default neutral-axis K-factor for a purely geometric unfold (mid-surface). */
 var DEFAULT_FOREIGN_K = .5;
@@ -1596,10 +1651,11 @@ function unfoldForeignSolid(solid, opts) {
 			message: `UNSUPPORTED_FACE: surface type '${t.value}' is not a planar panel or cylindrical bend; the unfold ignores it and may be incomplete`
 		});
 	}
-	const thicknessResult = detectThickness(planarFaces);
+	const planar = planarFaces.map(describePlanar);
+	const thicknessResult = detectThickness(planar);
 	if (!thicknessResult.ok) return thicknessResult;
 	const thickness = thicknessResult.value;
-	const flats = pairFlats(planarFaces, thickness, warnings);
+	const flats = pairFlats(planar, thickness, warnings);
 	if (flats.length === 0) return (0, brepjs.err)((0, brepjs.validationError)("NO_FLATS", "no planar panel pairs detected; not a recognizable sheet-metal solid"));
 	const layout = layoutForeign(flats, buildBendGraph(flats, pairBends(cylFaces, warnings), warnings), thickness, kFactor, warnings);
 	if (!layout.ok) return layout;
@@ -1609,59 +1665,106 @@ function unfoldForeignSolid(solid, opts) {
 		warnings
 	});
 }
+function describePlanar(face) {
+	const center = (0, brepjs.faceCenter)(face);
+	const n = 4;
+	const candidates = [center];
+	for (let i = 0; i < n; i += 1) for (let j = 0; j < n; j += 1) candidates.push((0, brepjs.pointOnSurface)(face, (i + .5) / n, (j + .5) / n));
+	const interior = candidates.filter((p) => liesOnFace(face, p));
+	return {
+		face,
+		normal: faceNormal(face),
+		center,
+		interior
+	};
+}
+/** True if `point` (already on the face's surface) lies within the face's trimmed boundary. */
+function liesOnFace(face, point) {
+	try {
+		var _usingCtx$1 = _usingCtx();
+		const probe = _usingCtx$1.u((0, brepjs.vertex)(point));
+		const d = (0, brepjs.measureDistance)(probe, face);
+		return d.ok && d.value < GEOM_TOL;
+	} catch (_) {
+		_usingCtx$1.e = _;
+	} finally {
+		_usingCtx$1.d();
+	}
+}
+/** Normal-direction gap between two planar faces, or `null` unless they are antiparallel. */
+function antiparallelGap(a, b) {
+	if ((0, brepjs.vecDot)(a.normal, b.normal) > -.99) return null;
+	return Math.abs((0, brepjs.vecDot)((0, brepjs.vecSub)(b.center, a.center), a.normal));
+}
 /**
-* Detect the sheet thickness as the smallest gap between an antiparallel pair of
-* planar faces (the two faces of one flat panel). For a roughly-uniform-thickness
-* part this gap is the same across panels; a spread beyond tolerance warns.
+* Antiparallel faces are the two sides of one panel only if they face each other:
+* an interior point of one projects inside the other. The normal-direction gap
+* alone also matches faces that merely sit on parallel planes, e.g. a flange's end
+* cap and the adjacent flange's inner face across a corner. Their gap is the bend's
+* inner radius, which passes for the sheet thickness as T approaches or exceeds R.
+*/
+function facesOppose(a, b) {
+	return b.interior.some((p) => liesOnFace(a.face, projectToPlane(p, a.normal, a.center))) || a.interior.some((p) => liesOnFace(b.face, projectToPlane(p, b.normal, b.center)));
+}
+/**
+* Detect the sheet thickness as the smallest gap between two antiparallel planar
+* faces that oppose each other (the two faces of one flat panel).
 */
 function detectThickness(planar) {
-	const gaps = [];
+	const pairs = [];
 	for (let i = 0; i < planar.length; i += 1) for (let j = i + 1; j < planar.length; j += 1) {
-		const fa = planar[i];
-		const fb = planar[j];
-		if (fa === void 0 || fb === void 0) continue;
-		const na = faceNormal(fa);
-		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));
-		if (gap > GEOM_TOL) gaps.push(gap);
+		const a = planar[i];
+		const b = planar[j];
+		if (a === void 0 || b === void 0) continue;
+		const gap = antiparallelGap(a, b);
+		if (gap !== null && gap > GEOM_TOL) pairs.push({
+			gap,
+			a,
+			b
+		});
+	}
+	pairs.sort((p, q) => p.gap - q.gap);
+	const thinnest = pairs.find((p) => facesOppose(p.a, p.b));
+	if (thinnest === void 0) return (0, brepjs.err)((0, brepjs.validationError)("NO_THICKNESS", "could not detect a sheet thickness (no opposed planar pair)"));
+	return (0, brepjs.ok)(thinnest.gap);
+}
+/** Unused face opposing `a` whose gap is nearest the sheet thickness, within tolerance. */
+function bestOpposedPartner(planar, i, thickness, used) {
+	const a = planar[i];
+	if (a === void 0) return null;
+	const candidates = [];
+	for (let j = 0; j < planar.length; j += 1) {
+		const b = planar[j];
+		if (j === i || used.has(j) || b === void 0) continue;
+		const gap = antiparallelGap(a, b);
+		if (gap === null) continue;
+		const e = Math.abs(gap - thickness);
+		if (e <= thickness * .5 + GEOM_TOL) candidates.push({
+			j,
+			e
+		});
 	}
-	if (gaps.length === 0) return (0, brepjs.err)((0, brepjs.validationError)("NO_THICKNESS", "could not detect a sheet thickness (no opposed planar pair)"));
-	gaps.sort((a, b) => a - b);
-	return (0, brepjs.ok)(gaps[0]);
+	candidates.sort((p, q) => p.e - q.e);
+	const match = candidates.find((c) => {
+		const b = planar[c.j];
+		return b !== void 0 && facesOppose(a, b);
+	});
+	return match === void 0 ? null : match.j;
 }
 /**
-* Pair planar faces into flat panels: each panel is two parallel faces a
-* `thickness` apart with overlapping footprints. Greedy nearest-match by gap.
+* Pair planar faces into flat panels: each panel is two antiparallel faces a
+* `thickness` apart that oppose each other. Greedy nearest-match by gap.
 */
 function pairFlats(planar, thickness, warnings) {
 	const used = /* @__PURE__ */ new Set();
 	const flats = [];
 	for (let i = 0; i < planar.length; i += 1) {
 		if (used.has(i)) continue;
-		const fa = planar[i];
-		if (fa === void 0) continue;
-		const na = faceNormal(fa);
-		const ca = (0, brepjs.faceCenter)(fa);
-		let best = -1;
-		let bestErr = Infinity;
-		for (let j = 0; j < planar.length; j += 1) {
-			if (j === i || used.has(j)) continue;
-			const fb = planar[j];
-			if (fb === void 0) 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);
-			if (e < bestErr) {
-				bestErr = e;
-				best = j;
-			}
-		}
-		if (best < 0 || bestErr > thickness * .5 + GEOM_TOL) {
+		const pa = planar[i];
+		if (pa === void 0) continue;
+		const fa = pa.face;
+		const best = bestOpposedPartner(planar, i, thickness, used);
+		if (best === null) {
 			const db = (0, brepjs.getBounds)(fa);
 			const ext = [
 				db.xMax - db.xMin,
@@ -1675,7 +1778,9 @@ function pairFlats(planar, thickness, warnings) {
 			});
 			continue;
 		}
-		const fb = planar[best];
+		const pb = planar[best];
+		if (pb === void 0) continue;
+		const fb = pb.face;
 		used.add(i);
 		used.add(best);
 		const areaA = (0, brepjs.measureArea)(fa);
@@ -1698,8 +1803,8 @@ function pairFlats(planar, thickness, warnings) {
 		flats.push({
 			id: `flat-${flats.length}`,
 			faces: [fa, fb],
-			normal: na,
-			center: (0, brepjs.vecScale)((0, brepjs.vecAdd)(ca, (0, brepjs.faceCenter)(fb)), .5),
+			normal: pa.normal,
+			center: (0, brepjs.vecScale)((0, brepjs.vecAdd)(pa.center, pb.center), .5),
 			area
 		});
 	}

package/dist/brepjs-sheetmetal.js

@@ -1,4 +1,4 @@
-import { box, curveEndPoint, curveStartPoint, cut, cylinder, err, extrude, face, faceCenter, fuse, getBounds, getEdges, getFaces, getSolids, getSurfaceType, intersect, isErr, isOk, isPlanarWire, isSolid, isValid, line, measureArea, measureVolume, normalAt, ok, pointOnSurface, rotate, sharedEdges, translate, validationError, vecAdd, vecCross, vecDot, vecLength, vecNormalize, vecScale, vecSub, wire, wireLoop } from "brepjs";
+import { box, curveEndPoint, curveStartPoint, cut, cylinder, err, extrude, face, faceCenter, fuse, getBounds, getEdges, getFaces, getSolids, getSurfaceType, intersect, isErr, isOk, isPlanarWire, isSolid, isValid, line, measureArea, measureDistance, measureVolume, normalAt, ok, pointOnSurface, rotate, sharedEdges, translate, validationError, vecAdd, vecCross, vecDot, vecLength, vecNormalize, vecScale, vecSub, vertex, wire, wireLoop } from "brepjs";
 // src/materials.ts
 var DEFAULT_K_FACTOR = .44;
 function gauge(name, thickness, kFactor = DEFAULT_K_FACTOR) {
@@ -1285,6 +1285,61 @@ function reportFromLayout(layout) {
 		totalFlatSize: [maxX - minX, maxY - minY]
 	};
 }
+// \0@oxc-project+runtime@0.155.0/helpers/esm/usingCtx.js
+function _usingCtx() {
+	var r = "function" == typeof SuppressedError ? SuppressedError : function(r, e) {
+		var n = Error();
+		return n.name = "SuppressedError", n.error = r, n.suppressed = e, n;
+	}, e = {}, n = [];
+	function using(r, e) {
+		if (null != e) {
+			if (Object(e) !== e) throw new TypeError("using declarations can only be used with objects, functions, null, or undefined.");
+			if (r) var o = e[Symbol.asyncDispose || Symbol["for"]("Symbol.asyncDispose")];
+			if (void 0 === o && (o = e[Symbol.dispose || Symbol["for"]("Symbol.dispose")], r)) var t = o;
+			if ("function" != typeof o) throw new TypeError("Object is not disposable.");
+			t && (o = function o() {
+				try {
+					t.call(e);
+				} catch (r) {
+					return Promise.reject(r);
+				}
+			}), n.push({
+				v: e,
+				d: o,
+				a: r
+			});
+		} else r && n.push({
+			d: e,
+			a: r
+		});
+		return e;
+	}
+	return {
+		e,
+		u: using.bind(null, !1),
+		a: using.bind(null, !0),
+		d: function d() {
+			var o, t = this.e, s = 0;
+			function next() {
+				for (; o = n.pop();) try {
+					if (!o.a && 1 === s) return s = 0, n.push(o), Promise.resolve().then(next);
+					if (o.d) {
+						var r = o.d.call(o.v);
+						if (o.a) return s |= 2, Promise.resolve(r).then(next, err);
+					} else s |= 1;
+				} catch (r) {
+					return err(r);
+				}
+				if (1 === s) return t !== e ? Promise.reject(t) : Promise.resolve();
+				if (t !== e) throw t;
+			}
+			function err(n) {
+				return t = t !== e ? new r(n, t) : n, next();
+			}
+			return next();
+		}
+	};
+}
 // src/foreignUnfoldFns.ts
 /** Default neutral-axis K-factor for a purely geometric unfold (mid-surface). */
 var DEFAULT_FOREIGN_K = .5;
@@ -1595,10 +1650,11 @@ function unfoldForeignSolid(solid, opts) {
 			message: `UNSUPPORTED_FACE: surface type '${t.value}' is not a planar panel or cylindrical bend; the unfold ignores it and may be incomplete`
 		});
 	}
-	const thicknessResult = detectThickness(planarFaces);
+	const planar = planarFaces.map(describePlanar);
+	const thicknessResult = detectThickness(planar);
 	if (!thicknessResult.ok) return thicknessResult;
 	const thickness = thicknessResult.value;
-	const flats = pairFlats(planarFaces, thickness, warnings);
+	const flats = pairFlats(planar, thickness, warnings);
 	if (flats.length === 0) return err(validationError("NO_FLATS", "no planar panel pairs detected; not a recognizable sheet-metal solid"));
 	const layout = layoutForeign(flats, buildBendGraph(flats, pairBends(cylFaces, warnings), warnings), thickness, kFactor, warnings);
 	if (!layout.ok) return layout;
@@ -1608,59 +1664,106 @@ function unfoldForeignSolid(solid, opts) {
 		warnings
 	});
 }
+function describePlanar(face) {
+	const center = faceCenter(face);
+	const n = 4;
+	const candidates = [center];
+	for (let i = 0; i < n; i += 1) for (let j = 0; j < n; j += 1) candidates.push(pointOnSurface(face, (i + .5) / n, (j + .5) / n));
+	const interior = candidates.filter((p) => liesOnFace(face, p));
+	return {
+		face,
+		normal: faceNormal(face),
+		center,
+		interior
+	};
+}
+/** True if `point` (already on the face's surface) lies within the face's trimmed boundary. */
+function liesOnFace(face, point) {
+	try {
+		var _usingCtx$1 = _usingCtx();
+		const probe = _usingCtx$1.u(vertex(point));
+		const d = measureDistance(probe, face);
+		return d.ok && d.value < GEOM_TOL;
+	} catch (_) {
+		_usingCtx$1.e = _;
+	} finally {
+		_usingCtx$1.d();
+	}
+}
+/** Normal-direction gap between two planar faces, or `null` unless they are antiparallel. */
+function antiparallelGap(a, b) {
+	if (vecDot(a.normal, b.normal) > -.99) return null;
+	return Math.abs(vecDot(vecSub(b.center, a.center), a.normal));
+}
 /**
-* Detect the sheet thickness as the smallest gap between an antiparallel pair of
-* planar faces (the two faces of one flat panel). For a roughly-uniform-thickness
-* part this gap is the same across panels; a spread beyond tolerance warns.
+* Antiparallel faces are the two sides of one panel only if they face each other:
+* an interior point of one projects inside the other. The normal-direction gap
+* alone also matches faces that merely sit on parallel planes, e.g. a flange's end
+* cap and the adjacent flange's inner face across a corner. Their gap is the bend's
+* inner radius, which passes for the sheet thickness as T approaches or exceeds R.
+*/
+function facesOppose(a, b) {
+	return b.interior.some((p) => liesOnFace(a.face, projectToPlane(p, a.normal, a.center))) || a.interior.some((p) => liesOnFace(b.face, projectToPlane(p, b.normal, b.center)));
+}
+/**
+* Detect the sheet thickness as the smallest gap between two antiparallel planar
+* faces that oppose each other (the two faces of one flat panel).
 */
 function detectThickness(planar) {
-	const gaps = [];
+	const pairs = [];
 	for (let i = 0; i < planar.length; i += 1) for (let j = i + 1; j < planar.length; j += 1) {
-		const fa = planar[i];
-		const fb = planar[j];
-		if (fa === void 0 || fb === void 0) continue;
-		const na = faceNormal(fa);
-		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));
-		if (gap > GEOM_TOL) gaps.push(gap);
+		const a = planar[i];
+		const b = planar[j];
+		if (a === void 0 || b === void 0) continue;
+		const gap = antiparallelGap(a, b);
+		if (gap !== null && gap > GEOM_TOL) pairs.push({
+			gap,
+			a,
+			b
+		});
+	}
+	pairs.sort((p, q) => p.gap - q.gap);
+	const thinnest = pairs.find((p) => facesOppose(p.a, p.b));
+	if (thinnest === void 0) return err(validationError("NO_THICKNESS", "could not detect a sheet thickness (no opposed planar pair)"));
+	return ok(thinnest.gap);
+}
+/** Unused face opposing `a` whose gap is nearest the sheet thickness, within tolerance. */
+function bestOpposedPartner(planar, i, thickness, used) {
+	const a = planar[i];
+	if (a === void 0) return null;
+	const candidates = [];
+	for (let j = 0; j < planar.length; j += 1) {
+		const b = planar[j];
+		if (j === i || used.has(j) || b === void 0) continue;
+		const gap = antiparallelGap(a, b);
+		if (gap === null) continue;
+		const e = Math.abs(gap - thickness);
+		if (e <= thickness * .5 + GEOM_TOL) candidates.push({
+			j,
+			e
+		});
 	}
-	if (gaps.length === 0) return err(validationError("NO_THICKNESS", "could not detect a sheet thickness (no opposed planar pair)"));
-	gaps.sort((a, b) => a - b);
-	return ok(gaps[0]);
+	candidates.sort((p, q) => p.e - q.e);
+	const match = candidates.find((c) => {
+		const b = planar[c.j];
+		return b !== void 0 && facesOppose(a, b);
+	});
+	return match === void 0 ? null : match.j;
 }
 /**
-* Pair planar faces into flat panels: each panel is two parallel faces a
-* `thickness` apart with overlapping footprints. Greedy nearest-match by gap.
+* Pair planar faces into flat panels: each panel is two antiparallel faces a
+* `thickness` apart that oppose each other. Greedy nearest-match by gap.
 */
 function pairFlats(planar, thickness, warnings) {
 	const used = /* @__PURE__ */ new Set();
 	const flats = [];
 	for (let i = 0; i < planar.length; i += 1) {
 		if (used.has(i)) continue;
-		const fa = planar[i];
-		if (fa === void 0) continue;
-		const na = faceNormal(fa);
-		const ca = faceCenter(fa);
-		let best = -1;
-		let bestErr = Infinity;
-		for (let j = 0; j < planar.length; j += 1) {
-			if (j === i || used.has(j)) continue;
-			const fb = planar[j];
-			if (fb === void 0) 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);
-			if (e < bestErr) {
-				bestErr = e;
-				best = j;
-			}
-		}
-		if (best < 0 || bestErr > thickness * .5 + GEOM_TOL) {
+		const pa = planar[i];
+		if (pa === void 0) continue;
+		const fa = pa.face;
+		const best = bestOpposedPartner(planar, i, thickness, used);
+		if (best === null) {
 			const db = getBounds(fa);
 			const ext = [
 				db.xMax - db.xMin,
@@ -1674,7 +1777,9 @@ function pairFlats(planar, thickness, warnings) {
 			});
 			continue;
 		}
-		const fb = planar[best];
+		const pb = planar[best];
+		if (pb === void 0) continue;
+		const fb = pb.face;
 		used.add(i);
 		used.add(best);
 		const areaA = measureArea(fa);
@@ -1697,8 +1802,8 @@ function pairFlats(planar, thickness, warnings) {
 		flats.push({
 			id: `flat-${flats.length}`,
 			faces: [fa, fb],
-			normal: na,
-			center: vecScale(vecAdd(ca, faceCenter(fb)), .5),
+			normal: pa.normal,
+			center: vecScale(vecAdd(pa.center, pb.center), .5),
 			area
 		});
 	}

package/package.json

@@ -1,6 +1,6 @@
 {
   "name": "brepjs-sheetmetal",
-  "version": "0.4.0",
+  "version": "0.4.1",
   "description": "Sheet-metal CAD domain for brepjs — flange authoring, auto-miter, fold/unfold flat patterns",
   "keywords": [
     "sheet-metal",