cyclecad 3.6.0 → 3.7.0

package/app/js/modules/multi-physics.js

@@ -0,0 +1,1244 @@
+/**
+ * Multi-Physics Real-Time Simulation Module
+ * cycleCAD v3.4.0
+ *
+ * Integrates structural FEA, thermal analysis, modal analysis, and drop test simulation.
+ * Uses Three.js for visualization, iterative solvers for performance.
+ *
+ * @namespace window.CycleCAD.MultiPhysics
+ */
+
+window.CycleCAD = window.CycleCAD || {};
+
+window.CycleCAD.MultiPhysics = (() => {
+  'use strict';
+
+  // ========== STATE ==========
+  let scene = null;
+  let meshData = null;
+  let currentAnalysis = 'static';
+  let simulationState = {
+    isRunning: false,
+    progress: 0,
+    results: null,
+    deformedGeometry: null,
+    stressTexture: null,
+    originalPositions: null,
+    selectedProbe: null,
+  };
+
+  // Material database with mechanical + thermal properties
+  const MATERIALS = {
+    steel: {
+      name: 'Structural Steel',
+      density: 7850, // kg/m³
+      youngsModulus: 210e9, // Pa
+      poissonsRatio: 0.3,
+      yieldStress: 250e6, // Pa
+      thermalConductivity: 50, // W/m·K
+      specificHeat: 490, // J/kg·K
+      thermalExpansion: 12e-6, // 1/K
+    },
+    aluminum: {
+      name: 'Aluminum 6061',
+      density: 2700,
+      youngsModulus: 69e9,
+      poissonsRatio: 0.33,
+      yieldStress: 275e6,
+      thermalConductivity: 167,
+      specificHeat: 896,
+      thermalExpansion: 23.6e-6,
+    },
+    titanium: {
+      name: 'Titanium Grade 5',
+      density: 4510,
+      youngsModulus: 103e9,
+      poissonsRatio: 0.342,
+      yieldStress: 880e6,
+      thermalConductivity: 7.4,
+      specificHeat: 526,
+      thermalExpansion: 8.6e-6,
+    },
+    abs: {
+      name: 'ABS Plastic',
+      density: 1040,
+      youngsModulus: 2.3e9,
+      poissonsRatio: 0.35,
+      yieldStress: 40e6,
+      thermalConductivity: 0.2,
+      specificHeat: 1500,
+      thermalExpansion: 70e-6,
+    },
+  };
+
+  // ========== 1. MESH DISCRETIZATION ==========
+
+  /**
+   * Convert Three.js geometry to mesh with nodes and elements
+   * Uses surface triangles + interior sampling for tetrahedra-like structure
+   */
+  function discretizeMesh(geometry, resolution = 'medium') {
+    const posAttr = geometry.getAttribute('position');
+    const positions = posAttr.array;
+    const indices = geometry.index ? geometry.index.array : null;
+
+    // Extract unique nodes
+    const nodes = [];
+    const nodeMap = new Map();
+    const vertexCount = positions.length / 3;
+
+    for (let i = 0; i < vertexCount; i++) {
+      const x = positions[i * 3];
+      const y = positions[i * 3 + 1];
+      const z = positions[i * 3 + 2];
+      const key = `${x.toFixed(6)},${y.toFixed(6)},${z.toFixed(6)}`;
+      if (!nodeMap.has(key)) {
+        nodeMap.set(key, nodes.length);
+        nodes.push({ x, y, z, id: nodes.length });
+      }
+    }
+
+    // Build surface elements (triangles)
+    const elements = [];
+    if (indices) {
+      for (let i = 0; i < indices.length; i += 3) {
+        const i0 = indices[i];
+        const i1 = indices[i + 1];
+        const i2 = indices[i + 2];
+        const n0 = nodeMap.get(`${positions[i0*3].toFixed(6)},${positions[i0*3+1].toFixed(6)},${positions[i0*3+2].toFixed(6)}`);
+        const n1 = nodeMap.get(`${positions[i1*3].toFixed(6)},${positions[i1*3+1].toFixed(6)},${positions[i1*3+2].toFixed(6)}`);
+        const n2 = nodeMap.get(`${positions[i2*3].toFixed(6)},${positions[i2*3+1].toFixed(6)},${positions[i2*3+2].toFixed(6)}`);
+        if (n0 !== undefined && n1 !== undefined && n2 !== undefined) {
+          elements.push({ nodes: [n0, n1, n2], type: 'triangle', stress: 0, strain: 0 });
+        }
+      }
+    } else {
+      // If no indices, build triangles from vertex sequence
+      for (let i = 0; i < vertexCount - 2; i += 3) {
+        const key0 = `${positions[i*3].toFixed(6)},${positions[i*3+1].toFixed(6)},${positions[i*3+2].toFixed(6)}`;
+        const key1 = `${positions[(i+1)*3].toFixed(6)},${positions[(i+1)*3+1].toFixed(6)},${positions[(i+1)*3+2].toFixed(6)}`;
+        const key2 = `${positions[(i+2)*3].toFixed(6)},${positions[(i+2)*3+1].toFixed(6)},${positions[(i+2)*3+2].toFixed(6)}`;
+        const n0 = nodeMap.get(key0);
+        const n1 = nodeMap.get(key1);
+        const n2 = nodeMap.get(key2);
+        if (n0 !== undefined && n1 !== undefined && n2 !== undefined) {
+          elements.push({ nodes: [n0, n1, n2], type: 'triangle', stress: 0, strain: 0 });
+        }
+      }
+    }
+
+    // Mesh quality assessment
+    const meshQuality = assessMeshQuality(nodes, elements);
+
+    return {
+      nodes,
+      elements,
+      nodeMap,
+      quality: meshQuality,
+      elementCount: elements.length,
+      nodeCount: nodes.length,
+    };
+  }
+
+  /**
+   * Assess mesh quality: aspect ratio, skewness
+   */
+  function assessMeshQuality(nodes, elements) {
+    let totalAspectRatio = 0;
+    let totalSkewness = 0;
+    let count = 0;
+
+    elements.forEach(elem => {
+      if (elem.nodes.length === 3) {
+        const n0 = nodes[elem.nodes[0]];
+        const n1 = nodes[elem.nodes[1]];
+        const n2 = nodes[elem.nodes[2]];
+
+        const e1 = { x: n1.x - n0.x, y: n1.y - n0.y, z: n1.z - n0.z };
+        const e2 = { x: n2.x - n0.x, y: n2.y - n0.y, z: n2.z - n0.z };
+
+        const len1 = Math.sqrt(e1.x**2 + e1.y**2 + e1.z**2);
+        const len2 = Math.sqrt(e2.x**2 + e2.y**2 + e2.z**2);
+        const aspectRatio = Math.max(len1, len2) / Math.min(len1, len2);
+        totalAspectRatio += aspectRatio;
+
+        const dot = e1.x*e2.x + e1.y*e2.y + e1.z*e2.z;
+        const mag1 = Math.sqrt(e1.x**2 + e1.y**2 + e1.z**2);
+        const mag2 = Math.sqrt(e2.x**2 + e2.y**2 + e2.z**2);
+        const angle = mag1 > 0 && mag2 > 0 ? Math.acos(Math.max(-1, Math.min(1, dot/(mag1*mag2)))) : 0;
+        const skewness = Math.abs(angle - Math.PI/3) / (Math.PI/3);
+        totalSkewness += skewness;
+
+        count++;
+      }
+    });
+
+    return {
+      avgAspectRatio: count > 0 ? totalAspectRatio / count : 1,
+      avgSkewness: count > 0 ? totalSkewness / count : 0,
+      quality: count > 0 && (totalAspectRatio/count) < 5 ? 'good' : count > 0 && (totalAspectRatio/count) < 10 ? 'acceptable' : 'poor',
+    };
+  }
+
+  // ========== 2. STRUCTURAL FEA SOLVER ==========
+
+  /**
+   * Run linear static structural analysis
+   * Uses conjugate gradient solver for K·u = F
+   */
+  function solveStructural(material, loads, constraints) {
+    if (!meshData) return { error: 'No mesh data' };
+
+    const { nodes, elements } = meshData;
+    const nDOF = nodes.length * 3; // 3 DOF per node (x, y, z)
+
+    // Initialize global stiffness matrix (sparse, stored as COO)
+    const K = new SparseMatrix(nDOF);
+    const M = new SparseMatrix(nDOF); // Mass matrix for factor of safety
+
+    // Assemble element stiffness matrices
+    const E = material.youngsModulus;
+    const nu = material.poissonsRatio;
+    const rho = material.density;
+
+    // Simplified isotropic stiffness for triangular elements
+    const G = E / (2 * (1 + nu));
+    const lambda = (E * nu) / ((1 + nu) * (1 - 2*nu));
+
+    elements.forEach((elem, eIdx) => {
+      if (elem.nodes.length !== 3) return;
+
+      const n0 = nodes[elem.nodes[0]];
+      const n1 = nodes[elem.nodes[1]];
+      const n2 = nodes[elem.nodes[2]];
+
+      // Element vectors
+      const v1 = { x: n1.x - n0.x, y: n1.y - n0.y, z: n1.z - n0.z };
+      const v2 = { x: n2.x - n0.x, y: n2.y - n0.y, z: n2.z - n0.z };
+
+      // Area vector (cross product)
+      const area = 0.5 * Math.sqrt(
+        (v1.y*v2.z - v1.z*v2.y)**2 +
+        (v1.z*v2.x - v1.x*v2.z)**2 +
+        (v1.x*v2.y - v1.y*v2.x)**2
+      );
+
+      if (area < 1e-10) return;
+
+      // Simplified 3D spring element stiffness
+      const k_spring = (E * area) / Math.sqrt(v1.x**2 + v1.y**2 + v1.z**2 + 1e-10);
+
+      // Add to global stiffness (simplified)
+      const dof0 = elem.nodes[0] * 3;
+      const dof1 = elem.nodes[1] * 3;
+      const dof2 = elem.nodes[2] * 3;
+
+      [dof0, dof1, dof2].forEach(i => {
+        [dof0, dof1, dof2].forEach(j => {
+          K.add(i, j, i === j ? k_spring : -k_spring * 0.5);
+          if (i === j) M.add(i, j, rho * area / 3);
+        });
+      });
+    });
+
+    // Force vector
+    const F = new Float64Array(nDOF);
+    loads.forEach(load => {
+      if (load.type === 'point') {
+        const dof = load.nodeId * 3;
+        F[dof] += load.force.x || 0;
+        F[dof + 1] += load.force.y || 0;
+        F[dof + 2] += load.force.z || 0;
+      }
+    });
+
+    // Apply gravity
+    elements.forEach(elem => {
+      const nodeIds = elem.nodes;
+      nodeIds.forEach(nId => {
+        const dof = nId * 3 + 1; // Y-direction
+        F[dof] -= material.density * 9.81 * meshData.quality.avgAspectRatio * 0.01; // Simplified
+      });
+    });
+
+    // Boundary conditions: fix constrained DOFs
+    constraints.forEach(constraint => {
+      if (constraint.type === 'fixed') {
+        const dof = constraint.nodeId * 3;
+        K.set(dof, dof, 1e30);
+        K.set(dof + 1, dof + 1, 1e30);
+        K.set(dof + 2, dof + 2, 1e30);
+        F[dof] = 0;
+        F[dof + 1] = 0;
+        F[dof + 2] = 0;
+      }
+    });
+
+    // Solve K·u = F using conjugate gradient
+    const u = conjugateGradient(K, F, nDOF, 1000, 1e-6);
+
+    // Compute stresses
+    const stresses = computeStresses(u, material);
+
+    // Compute factor of safety
+    const maxStress = Math.max(...stresses);
+    const factorOfSafety = maxStress > 0 ? material.yieldStress / maxStress : Infinity;
+
+    return {
+      displacement: u,
+      stresses,
+      maxStress,
+      maxStressLocation: stresses.indexOf(maxStress),
+      avgStress: stresses.reduce((a, b) => a + b, 0) / stresses.length,
+      factorOfSafety,
+      converged: true,
+    };
+  }
+
+  /**
+   * Conjugate gradient iterative solver for Ax = b
+   */
+  function conjugateGradient(A, b, n, maxIter, tol) {
+    const x = new Float64Array(n);
+    let r = new Float64Array(b);
+    let p = new Float64Array(r);
+    let rsold = dotProduct(r, r);
+
+    for (let i = 0; i < maxIter; i++) {
+      const Ap = A.multiply(p);
+      const alpha = rsold / (dotProduct(p, Ap) + 1e-15);
+
+      for (let j = 0; j < n; j++) x[j] += alpha * p[j];
+      for (let j = 0; j < n; j++) r[j] -= alpha * Ap[j];
+
+      const rsnew = dotProduct(r, r);
+      if (Math.sqrt(rsnew) < tol) break;
+
+      const beta = rsnew / (rsold + 1e-15);
+      for (let j = 0; j < n; j++) p[j] = r[j] + beta * p[j];
+
+      rsold = rsnew;
+    }
+
+    return x;
+  }
+
+  /**
+   * Compute Von Mises stress from displacement field
+   */
+  function computeStresses(u, material) {
+    const { nodes, elements } = meshData;
+    const stresses = new Float64Array(elements.length);
+    const E = material.youngsModulus;
+    const nu = material.poissonsRatio;
+
+    elements.forEach((elem, idx) => {
+      if (elem.nodes.length !== 3) {
+        stresses[idx] = 0;
+        return;
+      }
+
+      const n0 = nodes[elem.nodes[0]];
+      const n1 = nodes[elem.nodes[1]];
+      const n2 = nodes[elem.nodes[2]];
+
+      // Strain at element center (simplified)
+      const du_dx = (u[elem.nodes[1]*3] - u[elem.nodes[0]*3]) / (n1.x - n0.x + 1e-10);
+      const du_dy = (u[elem.nodes[1]*3+1] - u[elem.nodes[0]*3+1]) / (n1.y - n0.y + 1e-10);
+      const du_dz = (u[elem.nodes[1]*3+2] - u[elem.nodes[0]*3+2]) / (n1.z - n0.z + 1e-10);
+
+      const strain = Math.sqrt(du_dx**2 + du_dy**2 + du_dz**2);
+      const stress = E * strain; // Hook's law (simplified)
+
+      // Von Mises (simplified)
+      stresses[idx] = Math.abs(stress) * (1 + 0.5 * (strain**2));
+    });
+
+    return stresses;
+  }
+
+  // ========== 3. THERMAL ANALYSIS ==========
+
+  /**
+   * Solve steady-state heat conduction: ∇·(k∇T) = Q
+   */
+  function solveThermal(material, heatSources, boundaryConditions) {
+    if (!meshData) return { error: 'No mesh data' };
+
+    const { nodes, elements } = meshData;
+    const n = nodes.length;
+
+    const K_thermal = new SparseMatrix(n);
+    const Q = new Float64Array(n);
+
+    const k = material.thermalConductivity;
+
+    elements.forEach(elem => {
+      if (elem.nodes.length !== 3) return;
+
+      const n0 = nodes[elem.nodes[0]];
+      const n1 = nodes[elem.nodes[1]];
+      const n2 = nodes[elem.nodes[2]];
+
+      const v1 = { x: n1.x - n0.x, y: n1.y - n0.y, z: n1.z - n0.z };
+      const v2 = { x: n2.x - n0.x, y: n2.y - n0.y, z: n2.z - n0.z };
+
+      const area = 0.5 * Math.sqrt(
+        (v1.y*v2.z - v1.z*v2.y)**2 +
+        (v1.z*v2.x - v1.x*v2.z)**2 +
+        (v1.x*v2.y - v1.y*v2.x)**2
+      );
+
+      const k_e = (k * area) / (Math.sqrt(v1.x**2 + v1.y**2 + v1.z**2) + 1e-10);
+
+      elem.nodes.forEach((i, ii) => {
+        elem.nodes.forEach((j, jj) => {
+          K_thermal.add(i, j, ii === jj ? k_e : -k_e);
+        });
+      });
+    });
+
+    // Add heat sources
+    heatSources.forEach(source => {
+      if (source.type === 'point') {
+        Q[source.nodeId] += source.magnitude || 100;
+      }
+    });
+
+    // Boundary conditions
+    boundaryConditions.forEach(bc => {
+      if (bc.type === 'fixed') {
+        K_thermal.set(bc.nodeId, bc.nodeId, 1e30);
+        Q[bc.nodeId] = bc.temperature * 1e30;
+      } else if (bc.type === 'convection') {
+        const h = bc.convectionCoeff || 10;
+        const T_inf = bc.ambientTemp || 293;
+        K_thermal.add(bc.nodeId, bc.nodeId, h);
+        Q[bc.nodeId] += h * T_inf;
+      }
+    });
+
+    const T = conjugateGradient(K_thermal, Q, n, 1000, 1e-6);
+
+    return {
+      temperature: T,
+      maxTemp: Math.max(...T),
+      minTemp: Math.min(...T),
+      avgTemp: T.reduce((a, b) => a + b, 0) / T.length,
+    };
+  }
+
+  // ========== 4. MODAL/FREQUENCY ANALYSIS ==========
+
+  /**
+   * Compute natural frequencies and mode shapes via power iteration
+   */
+  function solveModal(material, constraints, numModes = 6) {
+    if (!meshData) return { error: 'No mesh data' };
+
+    const { nodes, elements } = meshData;
+    const nDOF = nodes.length * 3;
+
+    // Build mass and stiffness matrices (same as structural)
+    const K = new SparseMatrix(nDOF);
+    const M = new SparseMatrix(nDOF);
+
+    const E = material.youngsModulus;
+    const nu = material.poissonsRatio;
+    const rho = material.density;
+
+    elements.forEach(elem => {
+      if (elem.nodes.length !== 3) return;
+
+      const n0 = nodes[elem.nodes[0]];
+      const n1 = nodes[elem.nodes[1]];
+      const n2 = nodes[elem.nodes[2]];
+
+      const v1 = { x: n1.x - n0.x, y: n1.y - n0.y, z: n1.z - n0.z };
+      const v2 = { x: n2.x - n0.x, y: n2.y - n0.y, z: n2.z - n0.z };
+
+      const area = 0.5 * Math.sqrt(
+        (v1.y*v2.z - v1.z*v2.y)**2 +
+        (v1.z*v2.x - v1.x*v2.z)**2 +
+        (v1.x*v2.y - v1.y*v2.x)**2
+      );
+
+      const k_spring = (E * area) / Math.sqrt(v1.x**2 + v1.y**2 + v1.z**2 + 1e-10);
+      const mass = rho * area / 3;
+
+      elem.nodes.forEach(i => {
+        elem.nodes.forEach(j => {
+          K.add(i * 3, j * 3, i === j ? k_spring : -k_spring * 0.5);
+          M.add(i * 3, j * 3, i === j ? mass : 0);
+        });
+      });
+    });
+
+    // Apply constraints
+    constraints.forEach(constraint => {
+      if (constraint.type === 'fixed') {
+        for (let d = 0; d < 3; d++) {
+          const dof = constraint.nodeId * 3 + d;
+          K.set(dof, dof, 1e30);
+          M.set(dof, dof, 1);
+        }
+      }
+    });
+
+    const modes = [];
+    for (let m = 0; m < Math.min(numModes, 6); m++) {
+      const v = new Float64Array(nDOF);
+      for (let i = 0; i < nDOF; i++) v[i] = Math.random();
+
+      // Power iteration: K·v = λ·M·v
+      let lambda = 1;
+      for (let iter = 0; iter < 20; iter++) {
+        const Kv = K.multiply(v);
+        const Mv = M.multiply(v);
+        const lambdaNew = dotProduct(v, Kv) / (dotProduct(v, Mv) + 1e-15);
+        const denom = Math.sqrt(dotProduct(Mv, Mv)) + 1e-15;
+        for (let i = 0; i < nDOF; i++) v[i] = Kv[i] / (denom + 1e-15);
+        lambda = lambdaNew;
+      }
+
+      const frequency = Math.sqrt(Math.max(0, lambda)) / (2 * Math.PI);
+      modes.push({
+        modeNumber: m + 1,
+        frequency,
+        shapeVector: new Float64Array(v),
+      });
+    }
+
+    return {
+      modes,
+      frequencies: modes.map(m => m.frequency),
+    };
+  }
+
+  // ========== 5. DROP TEST / IMPACT SIMULATION ==========
+
+  /**
+   * Simulate drop test with time-domain integration
+   */
+  function solveDropTest(material, dropHeight, orientation = 'flat') {
+    if (!meshData) return { error: 'No mesh data' };
+
+    const { nodes, elements } = meshData;
+
+    // Calculate impact velocity
+    const g = 9.81;
+    const v_impact = Math.sqrt(2 * g * dropHeight);
+
+    // Time integration (Newmark-beta)
+    const dt = 0.001; // 1ms time step
+    const maxTime = 0.5; // 0.5 second simulation
+    const nSteps = Math.floor(maxTime / dt);
+
+    const nDOF = nodes.length * 3;
+    const u = new Float64Array(nDOF); // displacement
+    const v = new Float64Array(nDOF); // velocity
+    const a = new Float64Array(nDOF); // acceleration
+
+    // Initial velocity (downward impact)
+    for (let i = 1; i < nodes.length; i++) {
+      v[i * 3 + 1] = -v_impact; // Y-direction
+    }
+
+    let maxStress = 0;
+    let maxStressTime = 0;
+    let peakDeceleration = 0;
+    const stressHistory = [];
+
+    // Time stepping
+    for (let step = 0; step < nSteps; step++) {
+      // Contact with ground (y = 0)
+      for (let i = 0; i < nodes.length; i++) {
+        const y = nodes[i].y + u[i * 3 + 1];
+        if (y < 0) {
+          u[i * 3 + 1] = -nodes[i].y; // Snap back to ground
+          v[i * 3 + 1] = Math.max(0, v[i * 3 + 1] * 0.7); // Damping on contact
+          a[i * 3 + 1] = 0;
+        }
+      }
+
+      // Update velocities and displacements
+      for (let i = 0; i < nDOF; i++) {
+        v[i] += a[i] * dt;
+        u[i] += v[i] * dt + 0.5 * a[i] * dt * dt;
+        a[i] *= 0.99; // Damping
+      }
+
+      // Compute peak deceleration
+      const decel = Math.max(...a.map(Math.abs));
+      peakDeceleration = Math.max(peakDeceleration, decel);
+
+      // Compute stresses at this time step
+      const elemStresses = [];
+      elements.forEach(elem => {
+        if (elem.nodes.length === 3) {
+          const stress = Math.abs(material.youngsModulus * Math.sqrt(
+            Math.pow((u[elem.nodes[0]*3+1] - u[elem.nodes[1]*3+1]), 2) +
+            Math.pow((u[elem.nodes[1]*3+1] - u[elem.nodes[2]*3+1]), 2) + 1e-10
+          ));
+          elemStresses.push(stress);
+        }
+      });
+
+      if (elemStresses.length > 0) {
+        const stepMaxStress = Math.max(...elemStresses);
+        stressHistory.push(stepMaxStress);
+        if (stepMaxStress > maxStress) {
+          maxStress = stepMaxStress;
+          maxStressTime = step * dt;
+        }
+      }
+    }
+
+    const factorOfSafety = maxStress > 0 ? material.yieldStress / maxStress : Infinity;
+    const passed = factorOfSafety >= 1.5;
+
+    return {
+      maxStress,
+      maxStressTime,
+      peakDeceleration,
+      factorOfSafety,
+      passed,
+      displacement: u,
+      stressHistory,
+      impactVelocity: v_impact,
+    };
+  }
+
+  // ========== 6. RESULT VISUALIZATION ==========
+
+  /**
+   * Apply heatmap visualization to mesh
+   */
+  function visualizeResults(results, resultType = 'stress') {
+    if (!scene || !meshData) return;
+
+    const { nodes, elements } = meshData;
+    const values = resultType === 'stress' ? results.stresses :
+                   resultType === 'displacement' ? results.displacement :
+                   resultType === 'temperature' ? results.temperature : results.stresses;
+
+    if (!values) return;
+
+    // Create canvas texture for heatmap
+    const canvas = document.createElement('canvas');
+    canvas.width = 512;
+    canvas.height = 512;
+    const ctx = canvas.getContext('2d');
+
+    const minVal = Math.min(...values);
+    const maxVal = Math.max(...values);
+    const range = maxVal - minVal + 1e-10;
+
+    // Draw heatmap gradient bar (for reference)
+    for (let i = 0; i < 512; i++) {
+      const val = minVal + (i / 512) * range;
+      const hue = (1 - (val - minVal) / range) * 240;
+      ctx.fillStyle = `hsl(${hue}, 100%, 50%)`;
+      ctx.fillRect(i, 0, 1, 20);
+    }
+
+    // Add stress data as small visualization elements
+    ctx.fillStyle = '#fff';
+    ctx.font = '12px monospace';
+    ctx.fillText(`Min: ${minVal.toExponential(2)}`, 10, 50);
+    ctx.fillText(`Max: ${maxVal.toExponential(2)}`, 10, 70);
+
+    const texture = new THREE.CanvasTexture(canvas);
+    simulationState.stressTexture = texture;
+
+    // Update geometry colors based on stress
+    const geometry = scene.getObjectByName('mainGeometry')?.geometry;
+    if (geometry) {
+      const colors = new Float32Array(nodes.length * 3);
+
+      elements.forEach((elem, idx) => {
+        const stress = values[idx] || 0;
+        const normalized = Math.max(0, Math.min(1, (stress - minVal) / range));
+        const hue = (1 - normalized) * 240;
+        const rgb = hslToRgb(hue, 100, 50);
+
+        elem.nodes.forEach(nId => {
+          colors[nId * 3] = rgb.r / 255;
+          colors[nId * 3 + 1] = rgb.g / 255;
+          colors[nId * 3 + 2] = rgb.b / 255;
+        });
+      });
+
+      geometry.setAttribute('color', new THREE.BufferAttribute(colors, 3));
+      geometry.computeVertexNormals();
+    }
+  }
+
+  /**
+   * Apply deformation to geometry
+   */
+  function visualizeDeformation(results, scale = 100) {
+    if (!scene || !meshData) return;
+
+    const geometry = scene.getObjectByName('mainGeometry')?.geometry;
+    if (!geometry) return;
+
+    const posAttr = geometry.getAttribute('position');
+    const positions = posAttr.array;
+
+    // Store original if not already done
+    if (!simulationState.originalPositions) {
+      simulationState.originalPositions = new Float32Array(positions);
+    }
+
+    const { nodes } = meshData;
+    const displacement = results.displacement;
+
+    for (let i = 0; i < nodes.length; i++) {
+      positions[i * 3] = simulationState.originalPositions[i * 3] + (displacement[i * 3] * scale);
+      positions[i * 3 + 1] = simulationState.originalPositions[i * 3 + 1] + (displacement[i * 3 + 1] * scale);
+      positions[i * 3 + 2] = simulationState.originalPositions[i * 3 + 2] + (displacement[i * 3 + 2] * scale);
+    }
+
+    posAttr.needsUpdate = true;
+    geometry.computeVertexNormals();
+    geometry.computeBoundingSphere();
+  }
+
+  /**
+   * Probe tool: get local values at clicked position
+   */
+  function probeAt(worldPos, results) {
+    if (!meshData) return null;
+
+    const { nodes } = meshData;
+    let closestNode = null;
+    let minDist = Infinity;
+
+    nodes.forEach((node, idx) => {
+      const dist = Math.sqrt(
+        (node.x - worldPos.x)**2 +
+        (node.y - worldPos.y)**2 +
+        (node.z - worldPos.z)**2
+      );
+      if (dist < minDist) {
+        minDist = dist;
+        closestNode = idx;
+      }
+    });
+
+    if (closestNode === null) return null;
+
+    return {
+      nodeId: closestNode,
+      position: nodes[closestNode],
+      stress: results.stresses ? results.stresses[closestNode] : null,
+      temperature: results.temperature ? results.temperature[closestNode] : null,
+      displacement: results.displacement ? {
+        x: results.displacement[closestNode * 3],
+        y: results.displacement[closestNode * 3 + 1],
+        z: results.displacement[closestNode * 3 + 2],
+      } : null,
+    };
+  }
+
+  // ========== UTILITIES ==========
+
+  /**
+   * Sparse matrix class using COO format
+   */
+  class SparseMatrix {
+    constructor(n) {
+      this.n = n;
+      this.entries = new Map(); // key: "i,j", value: coefficient
+    }
+
+    add(i, j, val) {
+      const key = `${i},${j}`;
+      this.entries.set(key, (this.entries.get(key) || 0) + val);
+    }
+
+    set(i, j, val) {
+      const key = `${i},${j}`;
+      this.entries.set(key, val);
+    }
+
+    multiply(x) {
+      const result = new Float64Array(this.n);
+      for (const [key, val] of this.entries) {
+        const [i, j] = key.split(',').map(Number);
+        result[i] += val * x[j];
+      }
+      return result;
+    }
+  }
+
+  /**
+   * Dot product of two vectors
+   */
+  function dotProduct(a, b) {
+    let sum = 0;
+    for (let i = 0; i < a.length; i++) sum += a[i] * b[i];
+    return sum;
+  }
+
+  /**
+   * HSL to RGB conversion
+   */
+  function hslToRgb(h, s, l) {
+    s /= 100;
+    l /= 100;
+    const k = n => (n + h / 30) % 12;
+    const a = s * Math.min(l, 1 - l);
+    const f = n => l - a * Math.max(-1, Math.min(k(n) - 3, Math.min(9 - k(n), 1)));
+    return {
+      r: Math.round(255 * f(0)),
+      g: Math.round(255 * f(8)),
+      b: Math.round(255 * f(4)),
+    };
+  }
+
+  // ========== INITIALIZATION & UI ==========
+
+  /**
+   * Initialize module with scene
+   */
+  function init(sceneRef) {
+    scene = sceneRef;
+
+    // Listen for geometry changes
+    if (window.CycleCAD && window.CycleCAD.events) {
+      window.CycleCAD.events.on('geometryUpdated', (geometry) => {
+        meshData = discretizeMesh(geometry, 'medium');
+      });
+    }
+  }
+
+  /**
+   * Get UI panel (HTML)
+   */
+  function getUI() {
+    const panel = document.createElement('div');
+    panel.className = 'multi-physics-panel';
+    panel.style.cssText = `
+      background: var(--bg-secondary, #252526);
+      color: var(--text-primary, #e0e0e0);
+      border: 1px solid var(--border-color, #3e3e42);
+      border-radius: 4px;
+      padding: 12px;
+      font-family: 'Segoe UI', sans-serif;
+      font-size: 12px;
+      max-width: 320px;
+      max-height: 600px;
+      overflow-y: auto;
+    `;
+
+    panel.innerHTML = `
+      <div style="margin-bottom: 12px;">
+        <h3 style="margin: 0 0 8px 0; font-size: 14px; font-weight: 600;">Multi-Physics Simulation</h3>
+
+        <!-- Analysis Type Selector -->
+        <label style="display: block; margin-bottom: 8px;">
+          Analysis Type:
+          <select id="analysisType" style="width: 100%; padding: 4px; background: var(--bg-primary, #1e1e1e); color: var(--text-primary, #e0e0e0); border: 1px solid var(--border-color, #3e3e42); border-radius: 2px;">
+            <option value="static">Structural (Static FEA)</option>
+            <option value="thermal">Thermal</option>
+            <option value="modal">Modal (Frequencies)</option>
+            <option value="droptest">Drop Test / Impact</option>
+          </select>
+        </label>
+
+        <!-- Material Selector -->
+        <label style="display: block; margin-bottom: 8px;">
+          Material:
+          <select id="materialSelect" style="width: 100%; padding: 4px; background: var(--bg-primary, #1e1e1e); color: var(--text-primary, #e0e0e0); border: 1px solid var(--border-color, #3e3e42); border-radius: 2px;">
+            <option value="steel">Structural Steel</option>
+            <option value="aluminum">Aluminum 6061</option>
+            <option value="titanium">Titanium Grade 5</option>
+            <option value="abs">ABS Plastic</option>
+          </select>
+        </label>
+
+        <!-- Mesh Resolution -->
+        <label style="display: block; margin-bottom: 8px;">
+          Mesh Resolution:
+          <input type="range" id="meshResolution" min="1" max="3" value="2" style="width: 100%;">
+          <span id="meshResLabel" style="font-size: 11px; color: var(--text-secondary, #cccccc);">Medium</span>
+        </label>
+
+        <!-- Load Definition -->
+        <fieldset style="border: 1px solid var(--border-color, #3e3e42); border-radius: 2px; padding: 8px; margin-bottom: 8px;">
+          <legend style="padding: 0 4px; font-size: 11px; font-weight: 600;">Load Definition</legend>
+
+          <div style="margin-bottom: 6px;">
+            <label style="display: block; font-size: 11px;">Force (N):</label>
+            <input type="number" id="forceX" placeholder="X" min="-1000" max="1000" value="0" style="width: 32%; padding: 2px; margin-right: 2px;">
+            <input type="number" id="forceY" placeholder="Y" min="-1000" max="1000" value="-100" style="width: 32%; padding: 2px; margin-right: 2px;">
+            <input type="number" id="forceZ" placeholder="Z" min="-1000" max="1000" value="0" style="width: 32%; padding: 2px;">
+          </div>
+
+          <label style="display: block; margin-bottom: 4px;">
+            <input type="checkbox" id="applyGravity" checked>
+            <span style="font-size: 11px;">Include Gravity</span>
+          </label>
+        </fieldset>
+
+        <!-- Boundary Conditions -->
+        <fieldset style="border: 1px solid var(--border-color, #3e3e42); border-radius: 2px; padding: 8px; margin-bottom: 8px;">
+          <legend style="padding: 0 4px; font-size: 11px; font-weight: 600;">Constraints</legend>
+
+          <label style="display: block; margin-bottom: 4px;">
+            <input type="checkbox" id="fixBase" checked>
+            <span style="font-size: 11px;">Fix Base (Y=0)</span>
+          </label>
+        </fieldset>
+
+        <!-- Drop Test Parameters -->
+        <div id="dropTestParams" style="display: none; border: 1px solid var(--border-color, #3e3e42); border-radius: 2px; padding: 8px; margin-bottom: 8px;">
+          <label style="display: block; margin-bottom: 6px;">
+            Drop Height (m):
+            <input type="number" id="dropHeight" min="0.1" max="10" step="0.1" value="1" style="width: 100%; padding: 4px; background: var(--bg-primary, #1e1e1e); color: var(--text-primary, #e0e0e0); border: 1px solid var(--border-color, #3e3e42); border-radius: 2px;">
+          </label>
+        </div>
+
+        <!-- Modal Parameters -->
+        <div id="modalParams" style="display: none; border: 1px solid var(--border-color, #3e3e42); border-radius: 2px; padding: 8px; margin-bottom: 8px;">
+          <label style="display: block; margin-bottom: 6px;">
+            Number of Modes (1-6):
+            <input type="number" id="numModes" min="1" max="6" value="6" style="width: 100%; padding: 4px; background: var(--bg-primary, #1e1e1e); color: var(--text-primary, #e0e0e0); border: 1px solid var(--border-color, #3e3e42); border-radius: 2px;">
+          </label>
+        </div>
+
+        <!-- Visualization Controls -->
+        <fieldset style="border: 1px solid var(--border-color, #3e3e42); border-radius: 2px; padding: 8px; margin-bottom: 8px;">
+          <legend style="padding: 0 4px; font-size: 11px; font-weight: 600;">Visualization</legend>
+
+          <label style="display: block; margin-bottom: 6px;">
+            Result Type:
+            <select id="resultType" style="width: 100%; padding: 4px; background: var(--bg-primary, #1e1e1e); color: var(--text-primary, #e0e0e0); border: 1px solid var(--border-color, #3e3e42); border-radius: 2px;">
+              <option value="stress">Von Mises Stress</option>
+              <option value="displacement">Displacement Magnitude</option>
+              <option value="temperature">Temperature</option>
+            </select>
+          </label>
+
+          <label style="display: block; margin-bottom: 4px;">
+            Deformation Scale:
+            <input type="range" id="deformScale" min="0" max="1000" value="100" style="width: 100%;">
+            <span id="deformLabel" style="font-size: 11px; color: var(--text-secondary, #cccccc);">100×</span>
+          </label>
+        </fieldset>
+
+        <!-- Results Section -->
+        <div id="resultsSection" style="display: none; background: var(--bg-primary, #1e1e1e); border-radius: 2px; padding: 8px; margin-bottom: 8px; border: 1px solid var(--border-color, #3e3e42);">
+          <h4 style="margin: 0 0 6px 0; font-size: 12px; font-weight: 600;">Results</h4>
+          <div id="resultsList" style="font-size: 11px; line-height: 1.6;">
+            <!-- Populated dynamically -->
+          </div>
+        </div>
+
+        <!-- Progress Bar -->
+        <div id="progressContainer" style="display: none; margin-bottom: 8px;">
+          <div style="background: var(--bg-primary, #1e1e1e); border: 1px solid var(--border-color, #3e3e42); border-radius: 2px; overflow: hidden; height: 20px;">
+            <div id="progressBar" style="background: linear-gradient(90deg, var(--accent-blue, #0284C7), var(--accent-green, #16a34a)); height: 100%; width: 0%; transition: width 0.1s;"></div>
+          </div>
+          <div id="progressText" style="font-size: 10px; margin-top: 2px; text-align: center;">0%</div>
+        </div>
+
+        <!-- Action Buttons -->
+        <div style="display: flex; gap: 6px;">
+          <button id="runButton" style="flex: 1; padding: 6px 8px; background: var(--accent-blue, #0284C7); color: white; border: none; border-radius: 2px; cursor: pointer; font-size: 12px; font-weight: 600;">Run Analysis</button>
+          <button id="resetButton" style="flex: 1; padding: 6px 8px; background: var(--border-color, #3e3e42); color: var(--text-primary, #e0e0e0); border: none; border-radius: 2px; cursor: pointer; font-size: 12px;">Reset</button>
+          <button id="exportButton" style="flex: 0.8; padding: 6px 8px; background: var(--border-color, #3e3e42); color: var(--text-primary, #e0e0e0); border: none; border-radius: 2px; cursor: pointer; font-size: 11px;">Export</button>
+        </div>
+      </div>
+    `;
+
+    // Event listeners
+    const analysisTypeSelect = panel.querySelector('#analysisType');
+    const dropTestParams = panel.querySelector('#dropTestParams');
+    const modalParams = panel.querySelector('#modalParams');
+    const meshResSlider = panel.querySelector('#meshResolution');
+    const meshResLabel = panel.querySelector('#meshResLabel');
+    const deformSlider = panel.querySelector('#deformScale');
+    const deformLabel = panel.querySelector('#deformLabel');
+    const runButton = panel.querySelector('#runButton');
+    const resetButton = panel.querySelector('#resetButton');
+    const exportButton = panel.querySelector('#exportButton');
+
+    analysisTypeSelect.addEventListener('change', (e) => {
+      currentAnalysis = e.target.value;
+      dropTestParams.style.display = currentAnalysis === 'droptest' ? 'block' : 'none';
+      modalParams.style.display = currentAnalysis === 'modal' ? 'block' : 'none';
+    });
+
+    meshResSlider.addEventListener('input', (e) => {
+      const labels = ['Coarse', 'Medium', 'Fine'];
+      meshResLabel.textContent = labels[parseInt(e.target.value) - 1];
+    });
+
+    deformSlider.addEventListener('input', (e) => {
+      deformLabel.textContent = `${e.target.value}×`;
+      if (simulationState.results) {
+        visualizeDeformation(simulationState.results, parseInt(e.target.value));
+      }
+    });
+
+    runButton.addEventListener('click', () => runAnalysis(panel));
+    resetButton.addEventListener('click', () => resetSimulation());
+    exportButton.addEventListener('click', () => exportResults(panel));
+
+    return panel;
+  }
+
+  /**
+   * Run selected analysis
+   */
+  function runAnalysis(panel) {
+    if (simulationState.isRunning || !meshData) return;
+
+    simulationState.isRunning = true;
+    simulationState.progress = 0;
+
+    const materialKey = panel.querySelector('#materialSelect').value;
+    const material = MATERIALS[materialKey];
+    const progressContainer = panel.querySelector('#progressContainer');
+    const progressBar = panel.querySelector('#progressBar');
+    const progressText = panel.querySelector('#progressText');
+
+    progressContainer.style.display = 'block';
+
+    const updateProgress = (pct) => {
+      simulationState.progress = pct;
+      progressBar.style.width = `${pct}%`;
+      progressText.textContent = `${Math.round(pct)}%`;
+    };
+
+    requestAnimationFrame(() => {
+      updateProgress(20);
+
+      setTimeout(() => {
+        let result;
+
+        if (currentAnalysis === 'static') {
+          const loads = [{
+            type: 'point',
+            nodeId: 0,
+            force: {
+              x: parseFloat(panel.querySelector('#forceX').value),
+              y: parseFloat(panel.querySelector('#forceY').value),
+              z: parseFloat(panel.querySelector('#forceZ').value),
+            },
+          }];
+
+          const constraints = panel.querySelector('#fixBase').checked ? [{
+            type: 'fixed',
+            nodeId: meshData.nodes.length - 1,
+          }] : [];
+
+          result = solveStructural(material, loads, constraints);
+        } else if (currentAnalysis === 'thermal') {
+          const heatSources = [{
+            type: 'point',
+            nodeId: 0,
+            magnitude: 100,
+          }];
+
+          const bc = [{
+            type: 'fixed',
+            nodeId: meshData.nodes.length - 1,
+            temperature: 293,
+          }];
+
+          result = solveThermal(material, heatSources, bc);
+        } else if (currentAnalysis === 'modal') {
+          const numModes = parseInt(panel.querySelector('#numModes').value);
+          const constraints = [{
+            type: 'fixed',
+            nodeId: meshData.nodes.length - 1,
+          }];
+
+          result = solveModal(material, constraints, numModes);
+        } else if (currentAnalysis === 'droptest') {
+          const dropHeight = parseFloat(panel.querySelector('#dropHeight').value);
+          result = solveDropTest(material, dropHeight);
+        }
+
+        updateProgress(80);
+
+        if (result && !result.error) {
+          simulationState.results = result;
+          displayResults(panel, result);
+          visualizeResults(result, panel.querySelector('#resultType').value);
+          updateProgress(100);
+
+          setTimeout(() => {
+            progressContainer.style.display = 'none';
+            simulationState.isRunning = false;
+          }, 500);
+        }
+      }, 100);
+    });
+  }
+
+  /**
+   * Display results in panel
+   */
+  function displayResults(panel, results) {
+    const resultsSection = panel.querySelector('#resultsSection');
+    const resultsList = panel.querySelector('#resultsList');
+
+    resultsSection.style.display = 'block';
+    let html = '';
+
+    if (currentAnalysis === 'static') {
+      html = `
+        <div><strong>Max Stress:</strong> ${(results.maxStress / 1e6).toFixed(2)} MPa</div>
+        <div><strong>Avg Stress:</strong> ${(results.avgStress / 1e6).toFixed(2)} MPa</div>
+        <div><strong>Factor of Safety:</strong> ${results.factorOfSafety.toFixed(2)}</div>
+        <div style="color: ${results.factorOfSafety < 1 ? '#f87171' : results.factorOfSafety < 1.5 ? '#fbbf24' : '#86efac'};">
+          Status: ${results.factorOfSafety < 1 ? '⚠ FAILURE' : results.factorOfSafety < 1.5 ? '⚠ CAUTION' : '✓ SAFE'}
+        </div>
+      `;
+    } else if (currentAnalysis === 'thermal') {
+      html = `
+        <div><strong>Max Temp:</strong> ${results.maxTemp.toFixed(1)} K</div>
+        <div><strong>Min Temp:</strong> ${results.minTemp.toFixed(1)} K</div>
+        <div><strong>Avg Temp:</strong> ${results.avgTemp.toFixed(1)} K</div>
+      `;
+    } else if (currentAnalysis === 'modal') {
+      html = '<div><strong>Natural Frequencies:</strong></div>';
+      results.modes.forEach(mode => {
+        html += `<div style="padding-left: 8px;">Mode ${mode.modeNumber}: ${mode.frequency.toFixed(2)} Hz</div>`;
+      });
+    } else if (currentAnalysis === 'droptest') {
+      html = `
+        <div><strong>Impact Velocity:</strong> ${results.impactVelocity.toFixed(2)} m/s</div>
+        <div><strong>Peak Deceleration:</strong> ${(results.peakDeceleration / 9.81).toFixed(1)} g</div>
+        <div><strong>Max Stress:</strong> ${(results.maxStress / 1e6).toFixed(2)} MPa</div>
+        <div><strong>Factor of Safety:</strong> ${results.factorOfSafety.toFixed(2)}</div>
+        <div style="color: ${results.passed ? '#86efac' : '#f87171'};">
+          Result: ${results.passed ? '✓ PASS' : '✗ FAIL'}
+        </div>
+      `;
+    }
+
+    resultsList.innerHTML = html;
+  }
+
+  /**
+   * Reset simulation
+   */
+  function resetSimulation() {
+    simulationState = {
+      isRunning: false,
+      progress: 0,
+      results: null,
+      deformedGeometry: null,
+      stressTexture: null,
+      originalPositions: null,
+      selectedProbe: null,
+    };
+
+    // Restore original geometry
+    const geometry = scene?.getObjectByName('mainGeometry')?.geometry;
+    if (geometry && simulationState.originalPositions) {
+      const posAttr = geometry.getAttribute('position');
+      posAttr.array.set(simulationState.originalPositions);
+      posAttr.needsUpdate = true;
+      geometry.computeVertexNormals();
+      geometry.computeBoundingSphere();
+    }
+  }
+
+  /**
+   * Export results as JSON + CSV
+   */
+  function exportResults(panel) {
+    if (!simulationState.results) {
+      alert('Run an analysis first');
+      return;
+    }
+
+    const results = simulationState.results;
+    const json = JSON.stringify({
+      analysisType: currentAnalysis,
+      timestamp: new Date().toISOString(),
+      results: {
+        maxStress: results.maxStress,
+        maxStressLocation: results.maxStressLocation,
+        factorOfSafety: results.factorOfSafety,
+        frequencies: results.frequencies,
+      },
+    }, null, 2);
+
+    const link = document.createElement('a');
+    link.href = 'data:application/json;charset=utf-8,' + encodeURIComponent(json);
+    link.download = `simulation_${currentAnalysis}_${Date.now()}.json`;
+    link.click();
+  }
+
+  /**
+   * Execute command (for agent API)
+   */
+  function execute(command, params = {}) {
+    if (command === 'runFEA') {
+      return solveStructural(
+        MATERIALS[params.material] || MATERIALS.steel,
+        params.loads || [],
+        params.constraints || []
+      );
+    } else if (command === 'runThermal') {
+      return solveThermal(
+        MATERIALS[params.material] || MATERIALS.steel,
+        params.heatSources || [],
+        params.boundaryConditions || []
+      );
+    } else if (command === 'runModal') {
+      return solveModal(
+        MATERIALS[params.material] || MATERIALS.steel,
+        params.constraints || [],
+        params.numModes || 6
+      );
+    } else if (command === 'runDropTest') {
+      return solveDropTest(
+        MATERIALS[params.material] || MATERIALS.steel,
+        params.dropHeight || 1,
+        params.orientation || 'flat'
+      );
+    }
+    return { error: 'Unknown command' };
+  }
+
+  // ========== PUBLIC API ==========
+
+  return {
+    init,
+    getUI,
+    execute,
+    runSimulation: runAnalysis,
+    getResults: () => simulationState.results,
+    discretizeMesh,
+    solveStructural,
+    solveThermal,
+    solveModal,
+    solveDropTest,
+    visualizeResults,
+    visualizeDeformation,
+    probeAt,
+    resetSimulation,
+  };
+})();
+
+// Auto-init if in DOM
+if (document.readyState === 'loading') {
+  document.addEventListener('DOMContentLoaded', () => {
+    if (window.CycleCAD?.MultiPhysics?.init) {
+      window.CycleCAD.MultiPhysics.init(window.scene || null);
+    }
+  });
+} else {
+  if (window.CycleCAD?.MultiPhysics?.init) {
+    window.CycleCAD.MultiPhysics.init(window.scene || null);
+  }
+}