cyclecad 3.2.1 → 3.5.0

package/docs/BREP-LIVE-TEST-GUIDE.md

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+# B-Rep Live Test Guide — OpenCascade.js WASM + Three.js
+
+**File location:** `/app/tests/brep-live-test.html`
+
+**Status:** Live testing tool for B-Rep (Boundary Representation) geometry operations using OpenCascade.js WASM binary and Three.js visualization.
+
+---
+
+## Overview
+
+This test page downloads the full OpenCascade.js WASM library (~50MB) directly in the browser and runs real B-Rep geometry operations (primitives, boolean operations, fillets, tessellation) with live 3D visualization.
+
+### Key Features:
+- **Live WASM Loading** — Downloads OpenCascade.js WASM with progress bar
+- **14 Test Categories** — Primitives (5), Operations (6), Analysis (3)
+- **Real B-Rep Geometry** — Not meshes or approximations — actual topological shapes
+- **Tessellation Pipeline** — `BRepMesh_IncrementalMesh` → triangle extraction → Three.js rendering
+- **Interactive Testing** — Click tests individually or run all
+- **Real-time Stats** — FPS, triangle count, vertex count, operation time
+- **Dark Theme UI** — VS Code-style sidebar, viewport, and log panel
+
+---
+
+## How to Run
+
+### Option 1: Local Browser
+```bash
+cd ~/cyclecad
+# Open in browser (needs HTTPS for Web APIs):
+python -m http.server 8000
+# Navigate to: https://localhost:8000/app/tests/brep-live-test.html
+# (or http://localhost:8000 for test purposes)
+```
+
+### Option 2: GitHub Pages
+```bash
+# After pushing to repo:
+https://vvlars-cmd.github.io/cyclecad/app/tests/brep-live-test.html
+```
+
+### What to Expect:
+1. **Page loads** — Header shows "WASM: Loading..." with progress bar
+2. **WASM downloads** — ~50MB download (1-3 minutes on typical connection)
+3. **Initialization** — OpenCascade.js factory function instantiated with WASM binary
+4. **Ready state** — "Run All Tests" button enables, status shows "Ready"
+5. **Click any test** or **Click "Run All Tests"**
+6. **3D viewport** shows rendered geometry
+7. **Log panel** shows timing and geometry stats
+
+---
+
+## Test Categories
+
+### Primitives (5 tests)
+Tests basic shape creation from OpenCascade.js WASM APIs.
+
+| Test | API | What It Validates |
+|------|-----|-------------------|
+| **Box** | `BRepPrimAPI_MakeBox_3(100, 50, 30)` | Basic rectangular solid creation |
+| **Cylinder** | `BRepPrimAPI_MakeCylinder_2(25, 60)` | Circular solid with radius and height |
+| **Sphere** | `BRepPrimAPI_MakeSphere_1(30)` | Spherical solid with radius |
+| **Cone** | `BRepPrimAPI_MakeCone_3(20, 5, 50)` | Tapered solid, two radii + height |
+| **Torus** | `BRepPrimAPI_MakeTorus_3(30, 8)` | Doughnut shape, major and minor radius |
+
+**Expected results:** All should tessellate into 1,000–5,000 triangles and render in blue.
+
+---
+
+### Operations (6 tests)
+Tests edge and boolean operations on B-Rep shapes.
+
+| Test | API | What It Validates |
+|------|-----|-------------------|
+| **Fillet** | `BRepFilletAPI_MakeFillet` + edge iterator | Smooth all edges of a box with 5mm radius |
+| **Chamfer** | `BRepFilletAPI_MakeChamfer` + edge iterator | Beveled edges of a box with 3mm chamfer |
+| **Union** | `BRepAlgoAPI_Fuse(box, cylinder)` | Boolean sum — combines two solids |
+| **Cut** | `BRepAlgoAPI_Cut(box, cylinder)` | Boolean subtraction — removes cylinder from box |
+| **Intersect** | `BRepAlgoAPI_Common(box, sphere)` | Boolean intersection — overlapping region only |
+| **Extrude** | `BRepPrimAPI_MakePrism(face, direction)` | Extrude a 2D face into 3D solid |
+
+**Expected results:**
+- **Fillet/Chamfer:** Edges round/bevel smoothly
+- **Union:** Two shapes merge into one
+- **Cut:** Cylindrical hole through box
+- **Intersect:** Partial overlap of box and sphere
+- **Extrude:** Face extruded 50mm in Z direction
+
+---
+
+### Analysis (3 tests)
+Tests topological analysis and mass properties.
+
+| Test | API | What It Validates |
+|------|-----|-------------------|
+| **Mass Properties** | `BRepGProp_GProps` (volume + area) | Volume and surface area calculation |
+| **Edge Count** | `TopExp_Explorer(shape, TopAbs_EDGE)` | Topological iterator counts edges |
+| **Face Count** | `TopExp_Explorer(shape, TopAbs_FACE)` | Topological iterator counts faces |
+
+**Expected results:**
+- **Mass:** Box (100×50×30) = 150,000 mm³, area = 22,000 mm²
+- **Edges:** Box = 12 edges (rectangular solid)
+- **Faces:** Box = 6 faces (rectangular solid)
+
+---
+
+## UI Layout
+
+```
+┌────────────────────────────────────────────────────────────────┐
+│  B-Rep Live Test — OpenCascade.js WASM + Three.js              │
+│  [WASM: 100%]                                  [Run All Tests]  │
+├──────────────┬──────────────────────────────────────────────────┤
+│ Tests (14)   │  3D Viewport                                     │
+│ [Run All]    │  ┌────────────────────────────────────────────┐  │
+│              │  │                                            │  │
+│ ✓ Box        │  │         [Blue Box — tessellated]          │  │
+│ ✓ Cylinder   │  │                                            │  │
+│ ✓ Fillet     │  │  FPS: 60                                   │  │
+│ ✕ Union      │  │  Triangles: 8,423                         │  │
+│ ⏳ Cut       │  │  Vertices: 4,521                          │  │
+│              │  │  Operation: Fillet (box + 5mm edges)      │  │
+│              │  └────────────────────────────────────────────┘  │
+├──────────────┴──────────────────────────────────────────────────┤
+│ [14:32:15] Box: 45.3ms, 2834 triangles                          │
+│ [14:32:16] Cylinder: 28.1ms, 1204 triangles                    │
+│ [14:32:17] Fillet: 89.2ms, 4521 triangles                      │
+│ [14:32:18] Union: FAILED — BRepAlgoAPI_Fuse not found          │
+└────────────────────────────────────────────────────────────────┘
+```
+
+### Sidebar (Left)
+- **Test List** — All 14 tests grouped by category
+- **Status Indicators:**
+  - `—` = Pending (not yet run)
+  - `⟳` = Running (in progress)
+  - `✓` = Passed (green border, time shown)
+  - `✕` = Failed (red border, time shown)
+- **Click to run individual test**
+
+### Viewport (Center/Right)
+- **3D view** of current geometry
+- **OrbitControls** — left-click drag to rotate, right-click drag to pan, scroll to zoom
+- **Grid floor** for reference
+- **Stats overlay** (top-right):
+  - FPS (frames per second)
+  - Triangle count
+  - Vertex count
+  - Current operation name
+
+### Footer (Bottom)
+- **Log panel** with timestamps
+- Shows operation names, timings, and results
+- Color-coded: green = success, red = error, yellow = warning
+- Auto-scrolls to latest entry
+
+---
+
+## Understanding the Tests
+
+### Tessellation Pipeline
+
+Each geometry operation follows this pipeline:
+
+```
+1. Create B-Rep Shape (OCP API)
+   └─ BRepPrimAPI_MakeBox, BRepAlgoAPI_Fuse, etc.
+
+2. Mesh the Shape
+   └─ BRepMesh_IncrementalMesh(shape, linearDeflection=0.1)
+
+3. Extract Triangles
+   └─ TopExp_Explorer → iterate faces → BRep_Tool.Triangulation
+   └─ Each face yields nodes[] and triangles[]
+
+4. Build Three.js Geometry
+   └─ BufferGeometry with vertices, indices, normals
+
+5. Render
+   └─ MeshStandardMaterial (blue, metallic)
+   └─ Fit camera to bounding box
+```
+
+### Deflection Parameter
+- **`linearDeflection = 0.1`** — Controls mesh coarseness
+- Smaller = finer mesh (more triangles, slower)
+- Larger = coarser mesh (fewer triangles, faster)
+- **0.1** is good balance for visualization
+
+---
+
+## Adding New Tests
+
+### Step 1: Add Test Definition
+In the `tests` array at the top of the script:
+
+```javascript
+const tests = [
+    // ... existing tests ...
+    { id: 'mytest', name: 'My Test (description)', category: 'NewCategory' },
+];
+```
+
+### Step 2: Add Test Implementation
+In the `runTest()` function, add an `else if` block:
+
+```javascript
+else if (testId === 'mytest') {
+    // Create B-Rep shape using OCP API
+    const shape = new oc.BRepPrimAPI_MakeSomething(...).Shape();
+
+    // Tessellate
+    const tessData = tessellateShape(shape);
+    if (!tessData) throw new Error('Tessellation failed');
+
+    // Render
+    const { triangleCount, vertexCount } = renderGeometry(tessData.vertices, tessData.indices);
+
+    // Log result
+    const elapsed = performance.now() - startTime;
+    log(`${test.name}: ${elapsed.toFixed(1)}ms, ${triangleCount} triangles`, 'success');
+    updateTestStatus(testId, 'passed', elapsed);
+}
+```
+
+### Step 3: Find the Right OCP API
+Consult OpenCascade.js documentation or OCCT source:
+
+**Common patterns:**
+- `new oc.BRepPrimAPI_MakeSomething(params).Shape()`
+- `new oc.BRepAlgoAPI_Operation(shape1, shape2).Shape()`
+- `new oc.BRepFilletAPI_Make*(shape).Add(...).Shape()`
+
+**Overload naming:**
+- `_1`, `_2`, `_3` suffixes = different parameter combinations
+- Try variants if one doesn't work
+
+**Example — Finding overloads for Box:**
+```javascript
+// Try these in order:
+new oc.BRepPrimAPI_MakeBox_1(aXmin, aYmin, aZmin, aXmax, aYmax, aZmax)
+new oc.BRepPrimAPI_MakeBox_2(aCorner, aX, aY, aZ)  // position + dimensions
+new oc.BRepPrimAPI_MakeBox_3(aX, aY, aZ)  // origin (0,0,0) + dimensions
+```
+
+---
+
+## Troubleshooting
+
+### WASM Download Fails
+**Error:** `Failed to fetch WASM: 404`
+
+**Cause:** CDN URL changed or WASM file moved
+
+**Fix:** Update `CDN_BASE` in the script:
+```javascript
+const CDN_BASE = 'https://cdn.jsdelivr.net/npm/opencascade.js@2.0.0-beta.b5ff984/dist/';
+```
+
+Verify latest beta version:
+```bash
+npm view opencascade.js dist-tags
+```
+
+---
+
+### WASM Hangs During Load
+**Error:** Page freezes, no progress update
+
+**Cause:** WASM is very large (~50MB) and browser tab may become unresponsive
+
+**Fix:** Wait 1-3 minutes. Check network tab in DevTools (F12 → Network). If nothing is downloading, refresh and try again.
+
+---
+
+### Test Shows "Tessellation Failed"
+**Error:** Operation creates shape but tessellation returns null
+
+**Cause:** Shape has no faces or bad topology
+
+**Fix:**
+1. Check operation result with `TopExp_Explorer` to count faces
+2. Verify linear deflection is reasonable (0.05–1.0)
+3. Some operations may require `ShapeUpgrade_ShapeFix`
+
+**Code to debug:**
+```javascript
+const faceExplorer = new oc.TopExp_Explorer(shape, oc.TopAbs_ShapeEnum.TopAbs_FACE);
+let faceCount = 0;
+while (faceExplorer.More()) {
+    faceCount++;
+    faceExplorer.Next();
+}
+console.log('Face count:', faceCount);
+```
+
+---
+
+### Test Fails: "BRepSomethingAPI Not Found"
+**Error:** `new oc.BRepSomethingAPI_MakeThing is not a function`
+
+**Cause:** API doesn't exist in this version of OpenCascade.js or wrong overload
+
+**Fix:**
+1. Check spelling (case-sensitive)
+2. Try `_1`, `_2`, `_3` overloads
+3. Some APIs may not be bound in WASM yet
+
+**Workaround:** Simplify the test or use alternative API:
+```javascript
+// Instead of complex operation, use primitive
+const shape = new oc.BRepPrimAPI_MakeSphere_1(30).Shape();
+```
+
+---
+
+### Viewport Shows Black Screen
+**Error:** Nothing renders, no error in log
+
+**Cause:** Camera positioned inside mesh
+
+**Fix:** Already handled by auto-fit logic:
+```javascript
+const bbox = new THREE.Box3().setFromObject(currentMesh);
+const size = bbox.getSize(new THREE.Vector3());
+const maxDim = Math.max(size.x, size.y, size.z);
+let cameraZ = Math.abs(maxDim / 2 / Math.tan(fov / 2)) * 1.5;
+camera.position.z = cameraZ;
+```
+
+If still black, check console (F12 → Console) for errors.
+
+---
+
+## Performance Notes
+
+### Expected Timings (on modern machine)
+- **Primitives:** 10–50ms per shape
+- **Fillet/Chamfer:** 50–150ms (depends on edge count)
+- **Boolean ops:** 20–100ms (depends on complexity)
+- **Tessellation:** 5–30ms (included in total)
+- **Rendering:** 1–5ms per frame (60 FPS target)
+
+### Memory Usage
+- **WASM binary:** ~50MB (loaded once)
+- **Per shape:** 1–10MB depending on tessellation detail
+
+---
+
+## API Reference — Common OCP Methods
+
+### Primitive Creation
+```javascript
+new oc.BRepPrimAPI_MakeBox_3(sizeX, sizeY, sizeZ)
+new oc.BRepPrimAPI_MakeCylinder_2(radius, height)
+new oc.BRepPrimAPI_MakeSphere_1(radius)
+new oc.BRepPrimAPI_MakeCone_3(radius1, radius2, height)
+new oc.BRepPrimAPI_MakeTorus_3(majorRadius, minorRadius)
+```
+
+### Boolean Operations
+```javascript
+new oc.BRepAlgoAPI_Fuse(shape1, shape2)           // Union
+new oc.BRepAlgoAPI_Cut(shape1, shape2)            // Subtraction
+new oc.BRepAlgoAPI_Common(shape1, shape2)         // Intersection
+```
+
+### Edge/Face Operations
+```javascript
+new oc.BRepFilletAPI_MakeFillet(shape)            // Fillet edges
+new oc.BRepFilletAPI_MakeChamfer(shape)           // Chamfer edges
+makeFillet.Add(radius, edge)                      // Add edge to fillet
+```
+
+### Tessellation
+```javascript
+new oc.BRepMesh_IncrementalMesh(shape, deflection)
+oc.BRep_Tool.Triangulation(face)                  // Get mesh data from face
+```
+
+### Topology Iteration
+```javascript
+new oc.TopExp_Explorer(shape, shapeType)  // shapeType: TopAbs_EDGE, TopAbs_FACE, etc.
+explorer.More()                           // Check if more elements
+explorer.Current()                        // Get current element
+explorer.Next()                           // Move to next
+```
+
+### Properties
+```javascript
+new oc.GProp_GProps()
+oc.BRepGProp.VolumeProperties(shape, props)
+oc.BRepGProp.SurfaceProperties(shape, props)
+props.Mass()                              // Get mass (volume or area)
+```
+
+---
+
+## Debugging Tips
+
+### Enable Console Logging
+Open browser DevTools (F12) and check the **Console** tab for:
+- WASM download progress
+- Initialization messages
+- Operation timings
+- Error messages from OCP API
+
+### Check Network Tab
+**F12 → Network** to see:
+- `opencascade.full.js` (404KB, should complete in <1s)
+- `opencascade.full.wasm` (50MB, should complete in 1–3 minutes depending on connection)
+
+### Inspect 3D Geometry
+In browser console, access globals:
+```javascript
+// Inspect scene
+console.log(window.scene);
+console.log(window.currentMesh);
+
+// Check geometry stats
+console.log(window.currentMesh.geometry);
+console.log(window.currentMesh.geometry.attributes.position.count);
+```
+
+---
+
+## Next Steps
+
+### Integration with cycleCAD
+This test page validates that OpenCascade.js WASM works in the browser. Next:
+
+1. **Integrate into cycleCAD app** — Add real B-Rep operations to `operations.js`
+2. **STEP import** — Use `occt-import-js` or OpenCascade.js to read STEP files
+3. **Export** — Implement STEP/IGES/BREP export via OCP API
+
+### Known Limitations
+- Some advanced OCP APIs may not be bound in WASM
+- Very large shapes (100k+ faces) may be slow
+- Linear deflection can be adjusted per operation
+- No constraint solving (2D sketch → 3D part)
+
+---
+
+## References
+
+- **OpenCascade.js**: https://github.com/donalffons/opencascade.js
+- **OCCT API Docs**: https://dev.opencascade.org/doc/refman/latest/html/
+- **Three.js r170**: https://threejs.org/docs/
+- **BRepMesh Guide**: https://dev.opencascade.org/doc/refman/latest/html/class_b_rep_mesh___incremental_mesh.html
+
+---
+
+**Last updated:** 2026-03-31
+**Status:** Ready for testing and extension