brepjs-sheetmetal 0.4.1 → 0.4.3

package/README.md

@@ -307,9 +307,13 @@ authored path. It reads only the B-rep:
 - **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.
+  axis line and radius come from a least-squares circle fit of the points projected onto the plane ⟂ axis,
+  taken relative to their centroid so a part a metre from the origin fits as precisely as one at it; 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. A
+  bend's inner and outer faces pair only when they share an axis line, differ in radius by the sheet
+  thickness, and overlap along the axis, so matching corner rounds or holes on two parallel walls stay
+  apart.
 - **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
@@ -324,8 +328,9 @@ fit a cylinder within tolerance all surface as warnings inside the `Ok` payload
 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 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.
+L-bracket, U-channel, and four-sided tray at thicknesses 1, 1.5, 2, and 3 against a 2 mm inner radius: as
+authored, with each side of the bent profile merged into one face as most CAD exports carry it, and placed a
+metre from the origin as parts in an assembly export are), reading only the solid, never the feature tree.
 
 ## Bend tables
 

package/dist/brepjs-sheetmetal.cjs

@@ -1393,15 +1393,20 @@ function fitCylinder(face) {
 	const axisDir = axisFromNormals(samples.map((s) => s.normal));
 	if (axisDir === null) return null;
 	const basis = perpBasis(axisDir);
-	const pts2 = samples.map((s) => [(0, brepjs.vecDot)(s.point, basis.e1), (0, brepjs.vecDot)(s.point, basis.e2)]);
-	const circle = fitCircle2(pts2);
-	if (circle === null) return null;
-	const axial = (0, brepjs.vecDot)(samples[0]?.point ?? [
+	let centroid = [
 		0,
 		0,
 		0
-	], axisDir);
-	const axisOrigin = (0, brepjs.vecAdd)((0, brepjs.vecAdd)((0, brepjs.vecScale)(basis.e1, circle.cx), (0, brepjs.vecScale)(basis.e2, circle.cy)), (0, brepjs.vecScale)(axisDir, axial));
+	];
+	for (const s of samples) centroid = (0, brepjs.vecAdd)(centroid, s.point);
+	centroid = (0, brepjs.vecScale)(centroid, 1 / samples.length);
+	const pts2 = samples.map((s) => {
+		const d = (0, brepjs.vecSub)(s.point, centroid);
+		return [(0, brepjs.vecDot)(d, basis.e1), (0, brepjs.vecDot)(d, basis.e2)];
+	});
+	const circle = fitCircle2(pts2);
+	if (circle === null) return null;
+	const axisOrigin = (0, brepjs.vecAdd)(centroid, (0, brepjs.vecAdd)((0, brepjs.vecScale)(basis.e1, circle.cx), (0, brepjs.vecScale)(basis.e2, circle.cy)));
 	let sumR = 0;
 	for (const s of samples) sumR += distanceToAxis(s.point, axisOrigin, axisDir);
 	const radius = sumR / samples.length;
@@ -1657,7 +1662,7 @@ function unfoldForeignSolid(solid, opts) {
 	const thickness = thicknessResult.value;
 	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);
+	const layout = layoutForeign(flats, buildBendGraph(flats, pairBends(cylFaces, thickness, warnings), warnings), thickness, kFactor, warnings);
 	if (!layout.ok) return layout;
 	return (0, brepjs.ok)({
 		pattern: layout.value.pattern,
@@ -1765,16 +1770,10 @@ function pairFlats(planar, thickness, warnings) {
 		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,
-				db.yMax - db.yMin,
-				db.zMax - db.zMin
-			].sort((p, q) => q - p);
-			const inPlaneMin = ext[1] ?? 0;
-			if (inPlaneMin > thickness * 4) warnings.push({
+			const size = inPlaneSize(fa);
+			if (size.short > thickness * 4) warnings.push({
 				code: "DETECTION_INCOMPLETE",
-				message: `a panel-sized planar face (${(ext[0] ?? 0).toFixed(1)}×${inPlaneMin.toFixed(1)}) has no opposite face at the sheet thickness ${thickness.toFixed(3)}; omitted (possible non-uniform thickness)`
+				message: `a panel-sized planar face (${size.long.toFixed(1)}×${size.short.toFixed(1)}) has no opposite face at the sheet thickness ${thickness.toFixed(3)}; omitted (possible non-uniform thickness)`
 			});
 			continue;
 		}
@@ -1815,10 +1814,61 @@ function pairFlats(planar, thickness, warnings) {
 	return flats;
 }
 /**
+* In-plane size of a planar face: the sides of the rectangle with the same area
+* and perimeter. Unlike a world-axis bounding box it ignores orientation, and a
+* strip of width w along any path (a merged side face tracing the whole bent
+* profile) measures w wide.
+*/
+function inPlaneSize(face) {
+	const area = (0, brepjs.measureArea)(face);
+	let perimeter = 0;
+	let measured = area.ok;
+	for (const edge of (0, brepjs.getEdges)(face)) {
+		const len = (0, brepjs.measureLength)(edge);
+		if (len.ok) perimeter += len.value;
+		else measured = false;
+	}
+	if (!measured || !area.ok) {
+		const b = (0, brepjs.getBounds)(face);
+		const ext = [
+			b.xMax - b.xMin,
+			b.yMax - b.yMin,
+			b.zMax - b.zMin
+		].sort((p, q) => q - p);
+		return {
+			long: ext[0] ?? 0,
+			short: ext[1] ?? 0
+		};
+	}
+	const half = perimeter / 2;
+	const disc = half * half - 4 * area.value;
+	const short = disc > 0 ? (half - Math.sqrt(disc)) / 2 : half / 2;
+	return {
+		long: half - short,
+		short
+	};
+}
+/**
+* The inner and outer faces of one bend share an axis line, differ in radius by
+* the sheet thickness, and cover the same stretch of the axis. A shared axis line
+* alone also matches separate features that happen to line up, such as matching
+* corner rounds or holes on two parallel walls.
+*/
+function isBendMate(a, b, thickness) {
+	const axis = a.fit.axisDir;
+	if (Math.abs((0, brepjs.vecDot)(axis, b.fit.axisDir)) < .99) return false;
+	if (distanceToAxis(b.fit.axisOrigin, a.fit.axisOrigin, axis) > GEOM_TOL * 10) return false;
+	const radiusGap = Math.abs(a.fit.radius - b.fit.radius);
+	if (Math.abs(radiusGap - thickness) > thickness * .5 + GEOM_TOL) return false;
+	const ra = axialRange(a.face, axis);
+	const rb = axialRange(b.face, axis);
+	return Math.min(ra.max, rb.max) - Math.max(ra.min, rb.min) > GEOM_TOL;
+}
+/**
 * Pair cylindrical faces into bends: each bend has an inner + outer coaxial face
 * (same axis, radii a thickness apart) or, failing a pair, a single fitted face.
 */
-function pairBends(cyl, warnings) {
+function pairBends(cyl, thickness, warnings) {
 	const fitted = [];
 	for (const face of cyl) {
 		const fit = fitCylinder(face);
@@ -1844,9 +1894,7 @@ function pairBends(cyl, warnings) {
 		for (let j = i + 1; j < fitted.length; j += 1) {
 			if (used.has(j)) continue;
 			const b = fitted[j];
-			if (b === void 0) continue;
-			if (Math.abs((0, brepjs.vecDot)(a.fit.axisDir, b.fit.axisDir)) < .99) continue;
-			if (distanceToAxis(b.fit.axisOrigin, a.fit.axisOrigin, a.fit.axisDir) > GEOM_TOL * 10) continue;
+			if (b === void 0 || !isBendMate(a, b, thickness)) continue;
 			mate = j;
 			break;
 		}
@@ -1991,20 +2039,21 @@ function layoutForeign(flats, graph, thickness, kFactor, warnings) {
 		const axis = bend.fit.axisDir;
 		const span = bendSpan.get(bend) ?? bendAxialExtent(bend);
 		const placement = placeChildFlat(parentPlace, child, bend, axis, span, dev.value);
+		const bendLine = segment2(placement.bendA, placement.bendB);
+		if (bendLine === null) {
+			warnings.push({
+				code: "DETECTION_INCOMPLETE",
+				message: `bend '${bend.id}' has no length along ${parent.id} (zero span, or an axis that crosses the flat instead of lying in it); ${child.id} and the flats beyond it are left out of the layout`,
+				featureId: bend.id
+			});
+			continue;
+		}
 		placed.set(tb.child, placement.child);
 		rects.push(placement.strip);
 		rects.push(flatRect2(placement.child));
 		bendLines.push({
 			id: bend.id,
-			line: (0, brepjs.line)([
-				placement.bendA[0],
-				placement.bendA[1],
-				0
-			], [
-				placement.bendB[0],
-				placement.bendB[1],
-				0
-			]),
+			line: bendLine,
 			angleDeg: bend.angleDeg,
 			direction,
 			inward: [-placement.outDir2[0], -placement.outDir2[1]]
@@ -2021,7 +2070,8 @@ function layoutForeign(flats, graph, thickness, kFactor, warnings) {
 	}
 	const bbox = aabb2(rects);
 	const outline = buildRectOutline2(bbox);
-	const outlineWire = (0, brepjs.wireLoop)(outline);
+	if (!outline.ok) return outline;
+	const outlineWire = (0, brepjs.wireLoop)(outline.value);
 	if (!outlineWire.ok) return outlineWire;
 	const pattern = {
 		outline: outlineWire.value,
@@ -2214,8 +2264,30 @@ function aabb2(rects) {
 		y1
 	};
 }
+/** A 2D segment as an edge, or `null` when it is too short or not finite to build one. */
+function segment2(a, b) {
+	const len = Math.hypot(b[0] - a[0], b[1] - a[1]);
+	if (!Number.isFinite(len) || len < GEOM_TOL) return null;
+	return (0, brepjs.line)([
+		a[0],
+		a[1],
+		0
+	], [
+		b[0],
+		b[1],
+		0
+	]);
+}
 function buildRectOutline2(b) {
-	return [
+	const w = b.x1 - b.x0;
+	const h = b.y1 - b.y0;
+	if (![
+		b.x0,
+		b.y0,
+		b.x1,
+		b.y1
+	].every(Number.isFinite) || w < GEOM_TOL || h < GEOM_TOL) return (0, brepjs.err)((0, brepjs.validationError)("DEGENERATE_LAYOUT", `the developed outline is degenerate (${w}×${h})`));
+	return (0, brepjs.ok)([
 		(0, brepjs.line)([
 			b.x0,
 			b.y0,
@@ -2252,21 +2324,27 @@ function buildRectOutline2(b) {
 			b.y0,
 			0
 		])
-	];
+	]);
 }
-/** Axial extent of a bend (its cylindrical face span along the fitted axis). */
-function bendAxialExtent(bend) {
-	const face = bend.faces[0];
-	if (face === void 0) return 0;
-	const axis = bend.fit.axisDir;
-	const samples = sampleFace(face, 6);
+/** Range of a face's sampled points along `axis`. */
+function axialRange(face, axis) {
 	let min = Infinity;
 	let max = -Infinity;
-	for (const s of samples) {
+	for (const s of sampleFace(face, 6)) {
 		const a = (0, brepjs.vecDot)(s.point, axis);
 		min = Math.min(min, a);
 		max = Math.max(max, a);
 	}
+	return {
+		min,
+		max
+	};
+}
+/** Axial extent of a bend (its cylindrical face span along the fitted axis). */
+function bendAxialExtent(bend) {
+	const face = bend.faces[0];
+	if (face === void 0) return 0;
+	const { min, max } = axialRange(face, bend.fit.axisDir);
 	return Number.isFinite(max - min) ? max - min : 0;
 }
 /**
@@ -4791,10 +4869,10 @@ function miterCut(part, plane) {
 	});
 }
 /**
-* Auto corner-miter between two adjacent flanges. The miter plane bisects the two
-* flanges' fold-up directions at their shared corner and is offset by half the gap,
-* so the cut falls on the flat/flange regions and never crosses a bend patch. The
-* single bisector cut trims both flanges to a clean mitered corner.
+* Auto corner-miter between two adjacent flanges. The miter plane is vertical at
+* their shared corner, bisects the two directions that point out of the part, and
+* is offset outward by half the gap. The single cut trims the ends of both flanges
+* to a clean mitered corner and leaves the base flat and the bend lines whole.
 */
 function autoMiterCorner(part, flangeIdA, flangeIdB, gap = 0) {
 	if (part.solid === void 0) return (0, brepjs.err)((0, brepjs.validationError)("NO_SOLID", "autoMiterCorner: part has no folded solid"));
@@ -4805,7 +4883,7 @@ function autoMiterCorner(part, flangeIdA, flangeIdB, gap = 0) {
 	const axisA = (0, brepjs.vecNormalize)(bendA.axisDir);
 	const axisB = (0, brepjs.vecNormalize)(bendB.axisDir);
 	const corner = cornerPoint(bendA.axisOrigin, axisA, bendB.axisOrigin, axisB);
-	const planeNormal = miterNormal(axisA, axisB);
+	const planeNormal = miterNormal(axisA, bendLineMid(part, bendA, axisA), axisB, bendLineMid(part, bendB, axisB), corner);
 	if (planeNormal === void 0) return (0, brepjs.err)((0, brepjs.validationError)("PARALLEL_FLANGES", "autoMiterCorner: flange bend axes are parallel; no corner to miter"));
 	const cutResult = miterCut(part, {
 		origin: (0, brepjs.vecAdd)(corner, (0, brepjs.vecScale)(planeNormal, gap * .5)),
@@ -4834,19 +4912,27 @@ function cornerPoint(originA, dirA, originB, dirB) {
 	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`.
-* The plane is spanned by the two axes (it contains the corner edge of each
-* flange); its normal is `dirA × dirB` rotated to bisect — equivalently the
-* normalized sum of the two run directions, which both lie perpendicular to the
-* respective axis in the part's run plane.
-*/
-function miterNormal(dirA, dirB) {
-	const cross = (0, brepjs.vecCross)(dirA, dirB);
-	if (Math.hypot(cross[0], cross[1], cross[2]) < 1e-9) return void 0;
-	const sum = (0, brepjs.vecAdd)(dirA, dirB);
-	if (Math.hypot(sum[0], sum[1], sum[2]) < 1e-9) return (0, brepjs.vecNormalize)(cross);
-	return (0, brepjs.vecNormalize)(sum);
+/** Midpoint of a bend line. The line starts at the axis origin and runs the span of its flange. */
+function bendLineMid(part, bend, axis) {
+	const span = part.flanges.find((f) => f.id === bend.id)?.span ?? 0;
+	return (0, brepjs.vecAdd)(bend.axisOrigin, (0, brepjs.vecScale)(axis, span / 2));
+}
+/**
+* Normal of the miter plane between two flanges whose bend axes are `dirA`/`dirB`:
+* the bisector of the two directions that point out of the part. The outward
+* direction of a flange is perpendicular to its bend axis in the plane of the two
+* axes, and points away from the bend line of the other flange (`midA`/`midB` are
+* the midpoints of the two bend lines). The bend axes do not give this direction:
+* their sum lies along the diagonal of the part, and a cut there removes half of it.
+*/
+function miterNormal(dirA, midA, dirB, midB, corner) {
+	const up = (0, brepjs.vecCross)(dirA, dirB);
+	if (Math.hypot(up[0], up[1], up[2]) < 1e-9) return void 0;
+	const outward = (dir, otherMid) => {
+		const run = (0, brepjs.vecNormalize)((0, brepjs.vecCross)(dir, up));
+		return (0, brepjs.vecDot)(run, (0, brepjs.vecSub)(otherMid, corner)) > 0 ? (0, brepjs.vecScale)(run, -1) : run;
+	};
+	return (0, brepjs.vecNormalize)((0, brepjs.vecAdd)(outward(dirA, midB), outward(dirB, midA)));
 }
 var Z_AXIS = [
 	0,

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, measureDistance, measureVolume, normalAt, ok, pointOnSurface, rotate, sharedEdges, translate, validationError, vecAdd, vecCross, vecDot, vecLength, vecNormalize, vecScale, vecSub, vertex, 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, measureLength, 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) {
@@ -1392,15 +1392,20 @@ function fitCylinder(face) {
 	const axisDir = axisFromNormals(samples.map((s) => s.normal));
 	if (axisDir === null) return null;
 	const basis = perpBasis(axisDir);
-	const pts2 = samples.map((s) => [vecDot(s.point, basis.e1), vecDot(s.point, basis.e2)]);
-	const circle = fitCircle2(pts2);
-	if (circle === null) return null;
-	const axial = vecDot(samples[0]?.point ?? [
+	let centroid = [
 		0,
 		0,
 		0
-	], axisDir);
-	const axisOrigin = vecAdd(vecAdd(vecScale(basis.e1, circle.cx), vecScale(basis.e2, circle.cy)), vecScale(axisDir, axial));
+	];
+	for (const s of samples) centroid = vecAdd(centroid, s.point);
+	centroid = vecScale(centroid, 1 / samples.length);
+	const pts2 = samples.map((s) => {
+		const d = vecSub(s.point, centroid);
+		return [vecDot(d, basis.e1), vecDot(d, basis.e2)];
+	});
+	const circle = fitCircle2(pts2);
+	if (circle === null) return null;
+	const axisOrigin = vecAdd(centroid, vecAdd(vecScale(basis.e1, circle.cx), vecScale(basis.e2, circle.cy)));
 	let sumR = 0;
 	for (const s of samples) sumR += distanceToAxis(s.point, axisOrigin, axisDir);
 	const radius = sumR / samples.length;
@@ -1656,7 +1661,7 @@ function unfoldForeignSolid(solid, opts) {
 	const thickness = thicknessResult.value;
 	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);
+	const layout = layoutForeign(flats, buildBendGraph(flats, pairBends(cylFaces, thickness, warnings), warnings), thickness, kFactor, warnings);
 	if (!layout.ok) return layout;
 	return ok({
 		pattern: layout.value.pattern,
@@ -1764,16 +1769,10 @@ function pairFlats(planar, thickness, warnings) {
 		const fa = pa.face;
 		const best = bestOpposedPartner(planar, i, thickness, used);
 		if (best === null) {
-			const db = getBounds(fa);
-			const ext = [
-				db.xMax - db.xMin,
-				db.yMax - db.yMin,
-				db.zMax - db.zMin
-			].sort((p, q) => q - p);
-			const inPlaneMin = ext[1] ?? 0;
-			if (inPlaneMin > thickness * 4) warnings.push({
+			const size = inPlaneSize(fa);
+			if (size.short > thickness * 4) warnings.push({
 				code: "DETECTION_INCOMPLETE",
-				message: `a panel-sized planar face (${(ext[0] ?? 0).toFixed(1)}×${inPlaneMin.toFixed(1)}) has no opposite face at the sheet thickness ${thickness.toFixed(3)}; omitted (possible non-uniform thickness)`
+				message: `a panel-sized planar face (${size.long.toFixed(1)}×${size.short.toFixed(1)}) has no opposite face at the sheet thickness ${thickness.toFixed(3)}; omitted (possible non-uniform thickness)`
 			});
 			continue;
 		}
@@ -1814,10 +1813,61 @@ function pairFlats(planar, thickness, warnings) {
 	return flats;
 }
 /**
+* In-plane size of a planar face: the sides of the rectangle with the same area
+* and perimeter. Unlike a world-axis bounding box it ignores orientation, and a
+* strip of width w along any path (a merged side face tracing the whole bent
+* profile) measures w wide.
+*/
+function inPlaneSize(face) {
+	const area = measureArea(face);
+	let perimeter = 0;
+	let measured = area.ok;
+	for (const edge of getEdges(face)) {
+		const len = measureLength(edge);
+		if (len.ok) perimeter += len.value;
+		else measured = false;
+	}
+	if (!measured || !area.ok) {
+		const b = getBounds(face);
+		const ext = [
+			b.xMax - b.xMin,
+			b.yMax - b.yMin,
+			b.zMax - b.zMin
+		].sort((p, q) => q - p);
+		return {
+			long: ext[0] ?? 0,
+			short: ext[1] ?? 0
+		};
+	}
+	const half = perimeter / 2;
+	const disc = half * half - 4 * area.value;
+	const short = disc > 0 ? (half - Math.sqrt(disc)) / 2 : half / 2;
+	return {
+		long: half - short,
+		short
+	};
+}
+/**
+* The inner and outer faces of one bend share an axis line, differ in radius by
+* the sheet thickness, and cover the same stretch of the axis. A shared axis line
+* alone also matches separate features that happen to line up, such as matching
+* corner rounds or holes on two parallel walls.
+*/
+function isBendMate(a, b, thickness) {
+	const axis = a.fit.axisDir;
+	if (Math.abs(vecDot(axis, b.fit.axisDir)) < .99) return false;
+	if (distanceToAxis(b.fit.axisOrigin, a.fit.axisOrigin, axis) > GEOM_TOL * 10) return false;
+	const radiusGap = Math.abs(a.fit.radius - b.fit.radius);
+	if (Math.abs(radiusGap - thickness) > thickness * .5 + GEOM_TOL) return false;
+	const ra = axialRange(a.face, axis);
+	const rb = axialRange(b.face, axis);
+	return Math.min(ra.max, rb.max) - Math.max(ra.min, rb.min) > GEOM_TOL;
+}
+/**
 * Pair cylindrical faces into bends: each bend has an inner + outer coaxial face
 * (same axis, radii a thickness apart) or, failing a pair, a single fitted face.
 */
-function pairBends(cyl, warnings) {
+function pairBends(cyl, thickness, warnings) {
 	const fitted = [];
 	for (const face of cyl) {
 		const fit = fitCylinder(face);
@@ -1843,9 +1893,7 @@ function pairBends(cyl, warnings) {
 		for (let j = i + 1; j < fitted.length; j += 1) {
 			if (used.has(j)) continue;
 			const b = fitted[j];
-			if (b === void 0) continue;
-			if (Math.abs(vecDot(a.fit.axisDir, b.fit.axisDir)) < .99) continue;
-			if (distanceToAxis(b.fit.axisOrigin, a.fit.axisOrigin, a.fit.axisDir) > GEOM_TOL * 10) continue;
+			if (b === void 0 || !isBendMate(a, b, thickness)) continue;
 			mate = j;
 			break;
 		}
@@ -1990,20 +2038,21 @@ function layoutForeign(flats, graph, thickness, kFactor, warnings) {
 		const axis = bend.fit.axisDir;
 		const span = bendSpan.get(bend) ?? bendAxialExtent(bend);
 		const placement = placeChildFlat(parentPlace, child, bend, axis, span, dev.value);
+		const bendLine = segment2(placement.bendA, placement.bendB);
+		if (bendLine === null) {
+			warnings.push({
+				code: "DETECTION_INCOMPLETE",
+				message: `bend '${bend.id}' has no length along ${parent.id} (zero span, or an axis that crosses the flat instead of lying in it); ${child.id} and the flats beyond it are left out of the layout`,
+				featureId: bend.id
+			});
+			continue;
+		}
 		placed.set(tb.child, placement.child);
 		rects.push(placement.strip);
 		rects.push(flatRect2(placement.child));
 		bendLines.push({
 			id: bend.id,
-			line: line([
-				placement.bendA[0],
-				placement.bendA[1],
-				0
-			], [
-				placement.bendB[0],
-				placement.bendB[1],
-				0
-			]),
+			line: bendLine,
 			angleDeg: bend.angleDeg,
 			direction,
 			inward: [-placement.outDir2[0], -placement.outDir2[1]]
@@ -2020,7 +2069,8 @@ function layoutForeign(flats, graph, thickness, kFactor, warnings) {
 	}
 	const bbox = aabb2(rects);
 	const outline = buildRectOutline2(bbox);
-	const outlineWire = wireLoop(outline);
+	if (!outline.ok) return outline;
+	const outlineWire = wireLoop(outline.value);
 	if (!outlineWire.ok) return outlineWire;
 	const pattern = {
 		outline: outlineWire.value,
@@ -2213,8 +2263,30 @@ function aabb2(rects) {
 		y1
 	};
 }
+/** A 2D segment as an edge, or `null` when it is too short or not finite to build one. */
+function segment2(a, b) {
+	const len = Math.hypot(b[0] - a[0], b[1] - a[1]);
+	if (!Number.isFinite(len) || len < GEOM_TOL) return null;
+	return line([
+		a[0],
+		a[1],
+		0
+	], [
+		b[0],
+		b[1],
+		0
+	]);
+}
 function buildRectOutline2(b) {
-	return [
+	const w = b.x1 - b.x0;
+	const h = b.y1 - b.y0;
+	if (![
+		b.x0,
+		b.y0,
+		b.x1,
+		b.y1
+	].every(Number.isFinite) || w < GEOM_TOL || h < GEOM_TOL) return err(validationError("DEGENERATE_LAYOUT", `the developed outline is degenerate (${w}×${h})`));
+	return ok([
 		line([
 			b.x0,
 			b.y0,
@@ -2251,21 +2323,27 @@ function buildRectOutline2(b) {
 			b.y0,
 			0
 		])
-	];
+	]);
 }
-/** Axial extent of a bend (its cylindrical face span along the fitted axis). */
-function bendAxialExtent(bend) {
-	const face = bend.faces[0];
-	if (face === void 0) return 0;
-	const axis = bend.fit.axisDir;
-	const samples = sampleFace(face, 6);
+/** Range of a face's sampled points along `axis`. */
+function axialRange(face, axis) {
 	let min = Infinity;
 	let max = -Infinity;
-	for (const s of samples) {
+	for (const s of sampleFace(face, 6)) {
 		const a = vecDot(s.point, axis);
 		min = Math.min(min, a);
 		max = Math.max(max, a);
 	}
+	return {
+		min,
+		max
+	};
+}
+/** Axial extent of a bend (its cylindrical face span along the fitted axis). */
+function bendAxialExtent(bend) {
+	const face = bend.faces[0];
+	if (face === void 0) return 0;
+	const { min, max } = axialRange(face, bend.fit.axisDir);
 	return Number.isFinite(max - min) ? max - min : 0;
 }
 /**
@@ -4790,10 +4868,10 @@ function miterCut(part, plane) {
 	});
 }
 /**
-* Auto corner-miter between two adjacent flanges. The miter plane bisects the two
-* flanges' fold-up directions at their shared corner and is offset by half the gap,
-* so the cut falls on the flat/flange regions and never crosses a bend patch. The
-* single bisector cut trims both flanges to a clean mitered corner.
+* Auto corner-miter between two adjacent flanges. The miter plane is vertical at
+* their shared corner, bisects the two directions that point out of the part, and
+* is offset outward by half the gap. The single cut trims the ends of both flanges
+* to a clean mitered corner and leaves the base flat and the bend lines whole.
 */
 function autoMiterCorner(part, flangeIdA, flangeIdB, gap = 0) {
 	if (part.solid === void 0) return err(validationError("NO_SOLID", "autoMiterCorner: part has no folded solid"));
@@ -4804,7 +4882,7 @@ function autoMiterCorner(part, flangeIdA, flangeIdB, gap = 0) {
 	const axisA = vecNormalize(bendA.axisDir);
 	const axisB = vecNormalize(bendB.axisDir);
 	const corner = cornerPoint(bendA.axisOrigin, axisA, bendB.axisOrigin, axisB);
-	const planeNormal = miterNormal(axisA, axisB);
+	const planeNormal = miterNormal(axisA, bendLineMid(part, bendA, axisA), axisB, bendLineMid(part, bendB, axisB), corner);
 	if (planeNormal === void 0) return err(validationError("PARALLEL_FLANGES", "autoMiterCorner: flange bend axes are parallel; no corner to miter"));
 	const cutResult = miterCut(part, {
 		origin: vecAdd(corner, vecScale(planeNormal, gap * .5)),
@@ -4833,19 +4911,27 @@ function cornerPoint(originA, dirA, originB, dirB) {
 	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`.
-* The plane is spanned by the two axes (it contains the corner edge of each
-* flange); its normal is `dirA × dirB` rotated to bisect — equivalently the
-* normalized sum of the two run directions, which both lie perpendicular to the
-* respective axis in the part's run plane.
-*/
-function miterNormal(dirA, dirB) {
-	const cross = vecCross(dirA, dirB);
-	if (Math.hypot(cross[0], cross[1], cross[2]) < 1e-9) return void 0;
-	const sum = vecAdd(dirA, dirB);
-	if (Math.hypot(sum[0], sum[1], sum[2]) < 1e-9) return vecNormalize(cross);
-	return vecNormalize(sum);
+/** Midpoint of a bend line. The line starts at the axis origin and runs the span of its flange. */
+function bendLineMid(part, bend, axis) {
+	const span = part.flanges.find((f) => f.id === bend.id)?.span ?? 0;
+	return vecAdd(bend.axisOrigin, vecScale(axis, span / 2));
+}
+/**
+* Normal of the miter plane between two flanges whose bend axes are `dirA`/`dirB`:
+* the bisector of the two directions that point out of the part. The outward
+* direction of a flange is perpendicular to its bend axis in the plane of the two
+* axes, and points away from the bend line of the other flange (`midA`/`midB` are
+* the midpoints of the two bend lines). The bend axes do not give this direction:
+* their sum lies along the diagonal of the part, and a cut there removes half of it.
+*/
+function miterNormal(dirA, midA, dirB, midB, corner) {
+	const up = vecCross(dirA, dirB);
+	if (Math.hypot(up[0], up[1], up[2]) < 1e-9) return void 0;
+	const outward = (dir, otherMid) => {
+		const run = vecNormalize(vecCross(dir, up));
+		return vecDot(run, vecSub(otherMid, corner)) > 0 ? vecScale(run, -1) : run;
+	};
+	return vecNormalize(vecAdd(outward(dirA, midB), outward(dirB, midA)));
 }
 var Z_AXIS = [
 	0,

package/dist/miterFns.d.ts

@@ -12,9 +12,9 @@ export interface MiterPlane {
  */
 export declare function miterCut(part: SheetMetalPart, plane: MiterPlane): Result<SheetMetalPart>;
 /**
- * Auto corner-miter between two adjacent flanges. The miter plane bisects the two
- * flanges' fold-up directions at their shared corner and is offset by half the gap,
- * so the cut falls on the flat/flange regions and never crosses a bend patch. The
- * single bisector cut trims both flanges to a clean mitered corner.
+ * Auto corner-miter between two adjacent flanges. The miter plane is vertical at
+ * their shared corner, bisects the two directions that point out of the part, and
+ * is offset outward by half the gap. The single cut trims the ends of both flanges
+ * to a clean mitered corner and leaves the base flat and the bend lines whole.
  */
 export declare function autoMiterCorner(part: SheetMetalPart, flangeIdA: string, flangeIdB: string, gap?: number): Result<SheetMetalPart>;

package/package.json

@@ -1,6 +1,6 @@
 {
   "name": "brepjs-sheetmetal",
-  "version": "0.4.1",
+  "version": "0.4.3",
   "description": "Sheet-metal CAD domain for brepjs — flange authoring, auto-miter, fold/unfold flat patterns",
   "keywords": [
     "sheet-metal",
@@ -53,7 +53,7 @@
   },
   "devDependencies": {
     "@eslint/js": "*",
-    "@types/node": "26.6.5",
+    "@types/node": "26.6.6",
     "eslint": "*",
     "tsx": "4.23.15",
     "typescript": "*",