mcp-3d-printer-server 1.2.19 → 1.2.20

package/CHANGELOG.md

@@ -1,5 +1,15 @@
 # Changelog
 
+## 1.2.20 — 2026-10-30
+
+### Fixed
+
+- Keep already-horizontal faces eligible when `lay_flat` chooses the largest flat face. Thin plates now rest on their broad face at Z=0 instead of standing on an edge, including after repeated calls. When up- and down-facing areas tie exactly, as for a plate with a raised block or lettering, keep the face that already points down so a seated part is not flipped. Validate with generated STL geometry in horizontal, upside-down, edge-on, and tilted orientations and with a raised block in either face order; no printer or live Blender scene is used.
+
+### Tests
+
+- Verify malformed HTTP JSON returns a structured 400 response while the active MCP session remains usable. Exercise loopback HTTP only; no real printer or live Blender scene is used.
+
 ## 1.2.19 — 2026-10-30
 
 ### Fixed

package/dist/stl/stl-manipulator.js

@@ -1194,22 +1194,23 @@ export class STLManipulator extends EventEmitter {
                 throw new Error("Operation cancelled");
             if (progressCallback)
                 progressCallback(75, "Finding largest flat surface...");
-            // Find the group with the largest total area (excluding near-vertical faces)
+            // Include already-horizontal faces: excluding Z-aligned normals can
+            // stand a flat model on its edge, including on a repeated layFlat call.
             let largestArea = 0;
             let targetNormal = null;
-            const upVector = new THREE.Vector3(0, 1, 0); // Assuming Y is up for most models initially?
             const downVector = new THREE.Vector3(0, 0, -1); // Target normal (pointing down)
+            // Faces are grouped by direction, so a part whose flat faces are all
+            // horizontal has equal up- and down-facing areas. On a tie, keep the
+            // face that already points down so a seated part is not flipped.
             for (const group of normalGroups.values()) {
-                // Check if the normal is reasonably horizontal (not too close to vertical Z)
-                // Angle threshold could be adjusted (e.g., > 5 degrees from Z axis)
-                if (Math.abs(group.representativeNormal.z) < 0.99 && group.totalArea > largestArea) {
+                const tied = targetNormal !== null && Math.abs(group.totalArea - largestArea) <= largestArea * 1e-6;
+                if (tied ? group.representativeNormal.z < targetNormal.z : group.totalArea > largestArea) {
                     largestArea = group.totalArea;
                     targetNormal = group.representativeNormal;
                 }
             }
             if (!targetNormal) {
-                // If no suitable horizontal face found, maybe pick the lowest Z face?
-                // For now, throw an error or return unchanged.
+                // Only a mesh without any face area reaches this.
                 console.warn("Could not find a suitable large flat face to lay down. No changes made.");
                 this.emit('operationComplete', { operationId, type: 'layFlat', success: true, output: stlFilePath, message: "No suitable flat face found." });
                 return stlFilePath;

package/package.json

@@ -1,7 +1,7 @@
 {
     "name": "mcp-3d-printer-server",
     "mcpName": "io.github.DMontgomery40/mcp-3d-printer-server",
-    "version": "1.2.19",
+    "version": "1.2.20",
     "description": "MCP server for connecting Claude with 3D printer management systems",
     "main": "dist/index.js",
     "repository": "https://github.com/DMontgomery40/mcp-3D-printer-server",

package/server.json

@@ -7,12 +7,12 @@
     "url": "https://github.com/DMontgomery40/mcp-3D-printer-server",
     "source": "github"
   },
-  "version": "1.2.19",
+  "version": "1.2.20",
   "packages": [
     {
       "registryType": "npm",
       "identifier": "mcp-3d-printer-server",
-      "version": "1.2.19",
+      "version": "1.2.20",
       "runtimeHint": "npx",
       "transport": {
         "type": "stdio"

package/src/stl/stl-manipulator.ts

@@ -1503,24 +1503,25 @@ export class STLManipulator extends EventEmitter {
       if (!this.activeOperations.get(operationId)) throw new Error("Operation cancelled");
       if (progressCallback) progressCallback(75, "Finding largest flat surface...");
 
-      // Find the group with the largest total area (excluding near-vertical faces)
+      // Include already-horizontal faces: excluding Z-aligned normals can
+      // stand a flat model on its edge, including on a repeated layFlat call.
       let largestArea = 0;
       let targetNormal: THREE.Vector3 | null = null;
-      const upVector = new THREE.Vector3(0, 1, 0); // Assuming Y is up for most models initially?
       const downVector = new THREE.Vector3(0, 0, -1); // Target normal (pointing down)
 
+      // Faces are grouped by direction, so a part whose flat faces are all
+      // horizontal has equal up- and down-facing areas. On a tie, keep the
+      // face that already points down so a seated part is not flipped.
       for (const group of normalGroups.values()) {
-          // Check if the normal is reasonably horizontal (not too close to vertical Z)
-          // Angle threshold could be adjusted (e.g., > 5 degrees from Z axis)
-          if (Math.abs(group.representativeNormal.z) < 0.99 && group.totalArea > largestArea) {
+          const tied = targetNormal !== null && Math.abs(group.totalArea - largestArea) <= largestArea * 1e-6;
+          if (tied ? group.representativeNormal.z < targetNormal!.z : group.totalArea > largestArea) {
               largestArea = group.totalArea;
               targetNormal = group.representativeNormal;
           }
       }
 
       if (!targetNormal) {
-          // If no suitable horizontal face found, maybe pick the lowest Z face?
-          // For now, throw an error or return unchanged.
+          // Only a mesh without any face area reaches this.
           console.warn("Could not find a suitable large flat face to lay down. No changes made.");
           this.emit('operationComplete', { operationId, type: 'layFlat', success: true, output: stlFilePath, message: "No suitable flat face found." });
           return stlFilePath;