partforge 0.61.0 → 0.62.1

package/src/framework/geometry/mesh-fillet.js

@@ -0,0 +1,576 @@
+// Mesh fillet/chamfer for the Manifold backend — the tangent-wedge CSG technique
+// (independently reimplemented from the approach discussed in elalish/manifold
+// #1411): for each selected sharp edge chain, build a solid whose curved wall IS
+// the rolling-ball blend surface, then boolean it against the part. Convex chains
+// subtract a cutter; concave chains union a filler. Because the boolean runs in
+// Manifold, output is watertight by construction and the blend radius is exact to
+// tessellation.
+//
+// Edge classes supported:
+//   - straight chains with planar flanks           → lofted prism cutter
+//   - circular-arc chains with revolved flanks     → revolved cutter (bore rims,
+//     cylinder rims, the arcs where fillets meet a face), full circles included
+// Anything else (helical edges, varying dihedral, branching curves) raises
+// UnsupportedEdgeError so a caller can reroute the build to the B-rep backend.
+//
+// Known limits (documented, not bugs): no spherical corner patches yet — two
+// chains meeting at a vertex leave a mitred junction where their blend surfaces
+// intersect; radius feasibility is the caller's job (clamp like filleted-box.js
+// does — an oversized radius self-intersects the cutters).
+//
+// Selector object mirrors edge-selector.js semantics ({dir, inPlane, at, near});
+// `dir` only ever matches straight chains, like replicad's inDirection.
+// Pure module: no DOM, no node:, no three — safe anywhere in the worker graph.
+
+const TOL = 1e-4;            // selector / coplanarity tolerance (mm)
+const WELD = 1e6;            // vertex weld quantization (1/WELD mm grid)
+const COLLINEAR_DEG = 0.1;   // joints straighter than this extend a line run
+const SMOOTH_MAX_DEG = 30;   // joints turning more than this are corners (chain ends)
+const DEFAULT_SEGS = 116;    // full-circle tessellation density (preview quality)
+
+export class UnsupportedEdgeError extends Error {
+  constructor(message) { super(message); this.name = "UnsupportedEdgeError"; }
+}
+
+const sub = (a, b) => [a[0] - b[0], a[1] - b[1], a[2] - b[2]];
+const add = (a, b) => [a[0] + b[0], a[1] + b[1], a[2] + b[2]];
+const scl = (a, s) => [a[0] * s, a[1] * s, a[2] * s];
+const dot = (a, b) => a[0] * b[0] + a[1] * b[1] + a[2] * b[2];
+const cross = (a, b) => [a[1] * b[2] - a[2] * b[1], a[2] * b[0] - a[0] * b[2], a[0] * b[1] - a[1] * b[0]];
+const len = (a) => Math.hypot(a[0], a[1], a[2]);
+const norm = (a) => { const l = len(a); return l > 0 ? scl(a, 1 / l) : [0, 0, 0]; };
+const clamp1 = (x) => Math.max(-1, Math.min(1, x));
+const rotVec = (p, k, th) => { // Rodrigues rotation about unit axis k
+  const c = Math.cos(th), s = Math.sin(th);
+  return add(add(scl(p, c), scl(cross(k, p), s)), scl(k, dot(k, p) * (1 - c)));
+};
+
+// ---------------------------------------------------------------------------
+// Sharp-edge extraction: weld vertices, keep edges whose two incident triangles
+// meet at a dihedral sharper than sharpDeg, tag convexity and flank normals.
+export function detectSharpEdges({ positions, indices }, { sharpDeg = 20 } = {}) {
+  const nVert = positions.length / 3;
+  const weld = new Map(), wid = new Int32Array(nVert), pts = [];
+  for (let i = 0; i < nVert; i++) {
+    const x = positions[i * 3], y = positions[i * 3 + 1], z = positions[i * 3 + 2];
+    const key = `${Math.round(x * WELD)},${Math.round(y * WELD)},${Math.round(z * WELD)}`;
+    let id = weld.get(key);
+    if (id === undefined) { id = pts.length; weld.set(key, id); pts.push([x, y, z]); }
+    wid[i] = id;
+  }
+  const edges = new Map(); // "lo:hi" -> { u, v, faces: [{ n, w }] }
+  for (let t = 0; t < indices.length; t += 3) {
+    const ids = [wid[indices[t]], wid[indices[t + 1]], wid[indices[t + 2]]];
+    const [a, b, c] = ids.map((i) => pts[i]);
+    const n = norm(cross(sub(b, a), sub(c, a)));
+    if (len(n) === 0) continue; // degenerate sliver
+    for (let e = 0; e < 3; e++) {
+      const u = ids[e], v = ids[(e + 1) % 3], w = pts[ids[(e + 2) % 3]];
+      if (u === v) continue;
+      const key = u < v ? `${u}:${v}` : `${v}:${u}`;
+      let rec = edges.get(key);
+      if (!rec) { rec = { u, v, faces: [] }; edges.set(key, rec); }
+      rec.faces.push({ n, w });
+    }
+  }
+  const cosSharp = Math.cos((sharpDeg * Math.PI) / 180);
+  const out = [];
+  for (const { u, v, faces } of edges.values()) {
+    if (faces.length !== 2) continue;
+    const [f1, f2] = faces;
+    if (dot(f1.n, f2.n) > cosSharp) continue; // smooth or coplanar
+    const convex = dot(sub(f2.w, pts[u]), f1.n) < -1e-9;
+    out.push({ ua: u, ub: v, a: pts[u], b: pts[v], n1: f1.n, n2: f2.n, convex });
+  }
+  return out;
+}
+
+// ---------------------------------------------------------------------------
+// Chain sharp edges into straight and circular-arc runs.
+//
+// Walk maximal paths through the sharp-edge graph (vertices of degree ≠ 2 and
+// convexity flips end a path), classify each joint by turn angle, then split
+// paths into runs: collinear-joined stretches are line chains; stretches joined
+// by "circle-consistent" joints (small turn AND similar edge lengths — a long
+// straight edge next to tiny arc facets fails the length test and stays its own
+// line chain) are arc candidates, validated by a circumcircle fit. A loop with
+// no run boundary at all is a full circle.
+export function chainEdges(edges) {
+  const COS_COLL = Math.cos((COLLINEAR_DEG * Math.PI) / 180);
+  const COS_SMOOTH = Math.cos((SMOOTH_MAX_DEG * Math.PI) / 180);
+  const adj = new Map(); // welded vid -> [edge index...]
+  edges.forEach((e, i) => {
+    for (const v of [e.ua, e.ub]) (adj.get(v) ?? adj.set(v, []).get(v)).push(i);
+  });
+  const deg = (v) => adj.get(v).length;
+  const other = (e, v) => (e.ua === v ? e.ub : e.ua);
+  const used = new Array(edges.length).fill(false);
+
+  // orient edge e so it leaves vertex v: returns [from, to, dir]
+  const oriented = (e, v) => {
+    const from = v === e.ua ? e.a : e.b, to = v === e.ua ? e.b : e.a;
+    return { from, to, dir: norm(sub(to, from)) };
+  };
+
+  const paths = []; // { members: [edgeIdx...], verts: [vid...], loop }
+  const walk = (start, firstEdge) => {
+    const members = [firstEdge], verts = [start];
+    let v = start, e = firstEdge;
+    for (;;) {
+      used[e] = true;
+      const nv = other(edges[e], v);
+      verts.push(nv);
+      if (deg(nv) !== 2) break;
+      const next = adj.get(nv).find((i) => !used[i]);
+      if (next === undefined) break;
+      if (edges[next].convex !== edges[e].convex) break; // convexity flip ends the path
+      // turn angle gate: corners end paths
+      const d1 = oriented(edges[e], v).dir, d2 = oriented(edges[next], nv).dir;
+      if (dot(d1, d2) < COS_SMOOTH) break;
+      members.push(next);
+      v = nv; e = next;
+    }
+    return { members, verts, loop: verts[0] === verts[verts.length - 1] };
+  };
+  // open paths first (seeded at non-degree-2 vertices), then leftovers: loops,
+  // or open runs whose gates (turn/convexity) broke the walk mid-graph — those
+  // are walked in both directions from the seed and stitched
+  for (const [v, list] of adj) {
+    if (deg(v) === 2) continue;
+    for (const i of list) if (!used[i]) paths.push(walk(v, i));
+  }
+  edges.forEach((_, i) => {
+    if (used[i]) return;
+    const fwd = walk(edges[i].ua, i);
+    if (fwd.loop) { paths.push(fwd); return; }
+    // extend backward from the seed vertex if a compatible unused edge remains
+    const backSeed = adj.get(edges[i].ua).find((j) => !used[j]);
+    if (backSeed === undefined) { paths.push(fwd); return; }
+    const back = walk(other(edges[backSeed], edges[i].ua), backSeed);
+    paths.push({
+      members: [...back.members.slice().reverse(), ...fwd.members],
+      verts: [...back.verts.slice().reverse(), ...fwd.verts.slice(1)],
+      loop: false,
+    });
+  });
+
+  // split a path's member list into runs of "line" (collinear joints) and "arc"
+  // (circle-consistent joints) edges
+  const chains = [];
+  for (const path of paths) {
+    const { members, verts, loop } = path;
+    const dirs = members.map((i, k) => oriented(edges[i], verts[k]).dir);
+    const lens = members.map((i) => len(sub(edges[i].b, edges[i].a)));
+    const nJoint = loop ? members.length : members.length - 1; // joint j is between member j and j+1 (mod)
+    const jointType = []; // "coll" | "circ" | "cut"
+    for (let j = 0; j < nJoint; j++) {
+      const k2 = (j + 1) % members.length;
+      const c = dot(dirs[j], dirs[k2]);
+      const ratio = lens[j] / lens[k2];
+      if (c >= COS_COLL) jointType.push("coll");
+      else if (c >= COS_SMOOTH && ratio > 1 / 3 && ratio < 3) jointType.push("circ");
+      else jointType.push("cut");
+    }
+    // rotate loops so index 0 starts right after a run boundary; a loop with no
+    // boundary at all is a closed uniform curve (full circle candidate)
+    let order = members.map((_, k) => k);
+    let closedUniform = false;
+    if (loop) {
+      const boundary = jointType.findIndex((t, j) => t !== jointType[(j - 1 + nJoint) % nJoint] || t === "cut");
+      const cut = jointType.indexOf("cut");
+      const startAfter = cut !== -1 ? cut : boundary !== -1 ? boundary : -1;
+      if (startAfter === -1 && jointType.every((t) => t === jointType[0])) closedUniform = true;
+      else if (startAfter !== -1) order = order.map((k) => (startAfter + 1 + k) % members.length);
+    }
+    const runs = [];
+    let run = null;
+    for (let idx = 0; idx < order.length; idx++) {
+      const k = order[idx];
+      if (!run) { run = { type: null, ks: [k] }; continue; }
+      const t = jointType[order[idx - 1]]; // joint j joins member j and its successor
+      if (t === "cut" || (run.type !== null && run.type !== t)) { runs.push(run); run = { type: null, ks: [k] }; }
+      else { if (run.type === null) run.type = t; run.ks.push(k); }
+    }
+    if (run) runs.push(run);
+    // a run's type is the joint type joining its members; single-member runs are lines
+    for (const r of runs) {
+      const type = r.ks.length === 1 || r.type === "coll" || r.type === null ? "line" : "arc";
+      chains.push(buildChain(edges, path, r.ks, type, closedUniform && runs.length === 1));
+    }
+  }
+  return chains;
+}
+
+function buildChain(edges, path, ks, type, closed) {
+  // ks are positions along the path; path.members maps them to global edge indices
+  const members = ks.map((k) => edges[path.members[k]]);
+  const convex = members[0].convex;
+  // ordered polyline: the member at path position k runs path.verts[k] -> path.verts[k+1]
+  const points = [vertPos(members[0], path.verts[ks[0]])];
+  ks.forEach((k, i) => points.push(vertPos(members[i], otherVid(members[i], path.verts[k]))));
+  if (type !== "arc") {
+    // pair flank normals consistently against the first member (world frame is
+    // fine here — straight chains have near-constant flank normals)
+    const ref = members[0];
+    const flanks = members.map((m) => (dot(m.n1, ref.n1) >= dot(m.n2, ref.n1) ? [m.n1, m.n2] : [m.n2, m.n1]));
+    const a = points[0], b = points[points.length - 1];
+    const dir = norm(sub(b, a));
+    const n1 = norm(flanks.reduce((s, f) => add(s, f[0]), [0, 0, 0]));
+    const n2 = norm(flanks.reduce((s, f) => add(s, f[1]), [0, 0, 0]));
+    // planar-flank sanity: every member within ~3° of the mean
+    const planar = flanks.every((f) => dot(f[0], n1) > 0.9986 && dot(f[1], n2) > 0.9986);
+    if (!planar) return { kind: "unsupported", reason: "straight edge with non-planar flanks", points, convex };
+    return { kind: "line", points, a, b, dir, length: len(sub(b, a)), n1, n2, convex };
+  }
+  return fitArcChain(members, points, convex, closed);
+}
+const vertPos = (e, vid) => (vid === e.ua ? e.a : e.b);
+const otherVid = (e, vid) => (vid === e.ua ? e.ub : e.ua);
+
+// Circumcircle fit + rotating-frame flank extraction for an arc run.
+function fitArcChain(members, points, convex, closed) {
+  const bad = (reason) => ({ kind: "unsupported", reason, points, convex });
+  const n = points.length;
+  if (n < 3) return bad("arc run too short to fit");
+  const p0 = points[0], pm = points[Math.floor(n / 2)], pn = closed ? points[Math.floor((2 * n) / 3)] : points[n - 1];
+  // circumcircle of three points
+  const e1 = sub(pm, p0), e2 = sub(pn, p0);
+  const w0 = cross(e1, e2);
+  if (len(w0) < 1e-12) return bad("arc points are collinear");
+  const w = norm(w0);
+  const l1 = dot(e1, e1), l2 = dot(e2, e2), c12 = dot(e1, e2);
+  const det = 2 * (l1 * l2 - c12 * c12);
+  const alpha = (l2 * (l1 - c12)) / det, beta = (l1 * (l2 - c12)) / det;
+  const O = add(p0, add(scl(e1, alpha), scl(e2, beta)));
+  const R = len(sub(p0, O));
+  const rtol = Math.max(1e-3, 1e-3 * R);
+  for (const p of points) {
+    if (Math.abs(len(sub(p, O)) - R) > rtol) return bad("edge curve is not circular");
+    if (Math.abs(dot(sub(p, O), w)) > rtol) return bad("edge curve is not planar");
+  }
+  // frame: azimuth 0 at the first point; flip w so azimuths increase along the run
+  const u0 = norm(sub(points[0], O));
+  let v0 = cross(w, u0);
+  const az = (p) => Math.atan2(dot(sub(p, O), v0), dot(sub(p, O), u0));
+  let wS = w, v0S = v0;
+  if (!closed && az(points[1]) < 0) { wS = scl(w, -1); v0S = cross(wS, u0); }
+  else if (closed && az(points[1]) < 0) { wS = scl(w, -1); v0S = cross(wS, u0); }
+  const azS = (p) => { const a = Math.atan2(dot(sub(p, O), v0S), dot(sub(p, O), u0)); return a < -1e-9 ? a + 2 * Math.PI : a; };
+  let span = 2 * Math.PI;
+  if (!closed) {
+    let prev = 0;
+    for (let i = 1; i < n; i++) {
+      const a = azS(points[i]);
+      if (a < prev - 1e-9) return bad("arc azimuths not monotonic");
+      prev = a;
+    }
+    span = azS(points[n - 1]);
+  }
+  // rotating-frame flanks: constant (ρ, ζ) components, negligible azimuthal part.
+  // Pairing happens HERE, in the rotating frame — a revolved wall's world-space
+  // normal flips sign across the circle, so world-frame pairing would swap flanks
+  // on the far side.
+  const rfRaw = members.map((m) => {
+    const mid = scl(add(vertPos(m, m.ua), vertPos(m, m.ub)), 0.5);
+    const th = azS(mid);
+    const rho = add(scl(u0, Math.cos(th)), scl(v0S, Math.sin(th)));
+    const azv = cross(wS, rho);
+    return [m.n1, m.n2].map((f) => {
+      if (Math.abs(dot(f, azv)) > 0.2) return null; // not a surface of revolution about this axis
+      const v2 = [dot(f, rho), dot(f, wS)];
+      const l = Math.hypot(v2[0], v2[1]);
+      return [v2[0] / l, v2[1] / l];
+    });
+  });
+  if (rfRaw.some((pair) => pair.some((f) => f === null))) return bad("flank is not a surface of revolution about the edge axis");
+  const refRf = rfRaw[0];
+  const rf = rfRaw.map(([f1, f2]) =>
+    f1[0] * refRf[0][0] + f1[1] * refRf[0][1] >= f2[0] * refRf[0][0] + f2[1] * refRf[0][1] ? [f1, f2] : [f2, f1]);
+  const mean = (idx) => {
+    const s = rf.reduce((acc, pair) => [acc[0] + pair[idx][0], acc[1] + pair[idx][1]], [0, 0]);
+    const l = Math.hypot(s[0], s[1]); return [s[0] / l, s[1] / l];
+  };
+  const n1 = mean(0), n2 = mean(1);
+  const ok = rf.every((pair) => pair[0][0] * n1[0] + pair[0][1] * n1[1] > 0.9986 && pair[1][0] * n2[0] + pair[1][1] * n2[1] > 0.9986);
+  if (!ok) return bad("flank angle varies along the arc");
+  return { kind: "arc", points, O, w: wS, u0, v0: v0S, R, span, closed, n1, n2, convex };
+}
+
+// ---------------------------------------------------------------------------
+// Selector: the edge-selector.js object form, evaluated against a chain.
+const AXIS = { X: [1, 0, 0], Y: [0, 1, 0], Z: [0, 0, 1] };
+const PLANE_AXIS = { XY: 2, XZ: 1, YZ: 0 };
+export function matchesSelector(chain, sel) {
+  if (sel == null) return true;
+  if (typeof sel === "function")
+    throw new UnsupportedEdgeError("function selectors are OCCT-specific — use the {dir, inPlane, at, near} object form");
+  const { dir, inPlane, at, near } = sel;
+  if (dir !== undefined) {
+    if (chain.kind !== "line") return false; // like replicad inDirection: straight edges only
+    const d = Array.isArray(dir) ? norm(dir) : AXIS[dir];
+    if (!d) throw new Error(`mesh fillet: unknown dir ${JSON.stringify(dir)}`);
+    if (Math.abs(dot(chain.dir, d)) < Math.cos((1 * Math.PI) / 180)) return false;
+  }
+  if (inPlane !== undefined) {
+    const ax = PLANE_AXIS[inPlane];
+    if (ax === undefined) throw new Error(`mesh fillet: unknown inPlane ${JSON.stringify(inPlane)}`);
+    const c = at ?? 0;
+    if (!chain.points.every((p) => Math.abs(p[ax] - c) <= TOL)) return false;
+  }
+  if (near !== undefined) {
+    if (chain.kind === "arc") {
+      // Select against the fitted circle, not its tessellated chords. An exact
+      // design-space point between two mesh vertices sits one facet sagitta away
+      // from the chord and must not spuriously miss (and reroute to OCCT).
+      const q = sub(near, chain.O);
+      const axial = dot(q, chain.w);
+      const radial = sub(q, scl(chain.w, axial));
+      if (Math.abs(axial) > TOL || Math.abs(len(radial) - chain.R) > TOL) return false;
+      if (!chain.closed) {
+        let az = Math.atan2(dot(radial, chain.v0), dot(radial, chain.u0));
+        if (az < 0) az += 2 * Math.PI;
+        const angularTol = TOL / Math.max(chain.R, TOL);
+        if (az > chain.span + angularTol && 2 * Math.PI - az > angularTol) return false;
+      }
+    } else {
+      let best = Infinity;
+      for (let i = 0; i + 1 < chain.points.length; i++) {
+        const a = chain.points[i], b = chain.points[i + 1];
+        const ab = sub(b, a), t = Math.max(0, Math.min(1, dot(sub(near, a), ab) / (dot(ab, ab) || 1)));
+        best = Math.min(best, len(sub(near, add(a, scl(ab, t)))));
+      }
+      if (best > TOL) return false;
+    }
+  }
+  return true;
+}
+
+// ---------------------------------------------------------------------------
+// Shared 2D cross-section profile. P is the edge point, n1/n2 the unit flank
+// normals, all in the cross-section plane. Fillet connects the tangent points
+// with the rolling-ball arc; chamfer with a straight chord. Convex profiles
+// hang off the corner (oversized past it by delta so no cutter wall is exactly
+// coplanar with a flank); concave profiles tuck the corner point into the
+// material so the filler welds on.
+const rot2 = ([x, y], th) => [x * Math.cos(th) - y * Math.sin(th), x * Math.sin(th) + y * Math.cos(th)];
+function profile2D({ P, n1, n2, magnitude, mode, convex, segs, ext = 0 }) {
+  const c = clamp1(n1[0] * n2[0] + n1[1] * n2[1]);
+  if (1 + c < 1e-6) throw new UnsupportedEdgeError("~180° knife edge");
+  const bl = Math.hypot(n1[0] + n2[0], n1[1] + n2[1]);
+  const bis = [(n1[0] + n2[0]) / bl, (n1[1] + n2[1]) / bl];
+  const delta = 0.02 * magnitude;
+  const sgn = convex ? 1 : -1; // +bis is outside the material at a convex corner, inside at a concave one
+  const corner = [P[0] + sgn * delta * bis[0], P[1] + sgn * delta * bis[1]];
+  if (mode === "chamfer") {
+    // setback along each flank surface, away from the edge: perpendicular to the
+    // normal, on the material side of the bisector (which points out of the
+    // material at a convex corner and into the air pocket at a concave one)
+    const inFace = (nv) => {
+      let f = [-nv[1], nv[0]];
+      if (sgn * (f[0] * bis[0] + f[1] * bis[1]) > 0) f = [-f[0], -f[1]];
+      return f;
+    };
+    const f1 = inFace(n1), f2 = inFace(n2);
+    const T1 = [P[0] + magnitude * f1[0], P[1] + magnitude * f1[1]];
+    const T2 = [P[0] + magnitude * f2[0], P[1] + magnitude * f2[1]];
+    if (ext > 0) {
+      // revolve tools: extend the chord past both flanks so the tool's closing
+      // walls clear the flank tessellation instead of hugging it (same float
+      // phase-noise issue the fillet's arc extension solves); the extra polygon
+      // area lies outside the material for cutters and inside it for fillers
+      const ux = T1[0] - T2[0], uy = T1[1] - T2[1], ul = Math.hypot(ux, uy);
+      const e = 0.02 * magnitude;
+      T1[0] += (e * ux) / ul; T1[1] += (e * uy) / ul;
+      T2[0] -= (e * ux) / ul; T2[1] -= (e * uy) / ul;
+    }
+    return [corner, T1, T2];
+  }
+  const r = magnitude;
+  const C = [P[0] + sgn * (-r / (1 + c)) * (n1[0] + n2[0]), P[1] + sgn * (-r / (1 + c)) * (n1[1] + n2[1])];
+  const phi = Math.atan2(n1[0] * n2[1] - n1[1] * n2[0], c); // signed angle n1 → n2
+  // `ext` (radians) continues the arc a hair past both tangent points — used by
+  // revolve cutters only. At the tangent the blend surface touches the flank
+  // without crossing it; for two curved tessellations (posed revolve vs flank
+  // facets) float phase noise turns that contact into a wiggle of degenerate
+  // sliver triangles. Overshooting makes the cutter cross the flank decisively,
+  // penetrating the material by only r·(1−cos ext) ≈ r·5e-5 mm, far below
+  // visibility, and the extension curves into the material for cutters and
+  // fillers alike. Prism cutters keep ext = 0: their tangent contact is
+  // plane-on-plane, which the kernel resolves exactly.
+  const s2 = Math.sign(phi) || 1, span = Math.abs(phi);
+  const nArc = Math.max(2, Math.ceil((span / (2 * Math.PI)) * segs));
+  const pts = [corner];
+  for (let i = 0; i <= nArc; i++) {
+    const nv = rot2(n1, s2 * (-ext + ((span + 2 * ext) * i) / nArc));
+    pts.push([C[0] + sgn * r * nv[0], C[1] + sgn * r * nv[1]]);
+  }
+  return pts;
+}
+
+// ---------------------------------------------------------------------------
+// Cutter/filler solids.
+function prismTool(k, chain, magnitude, mode, segs) {
+  const { a, dir: e, length, n1, n2, convex } = chain;
+  // pose rotation Z → e; the 2D basis is the image of X,Y under the SAME rotation
+  const axisRaw = cross([0, 0, 1], e);
+  const s = len(axisRaw);
+  let axis = null, theta = 0;
+  if (s > 1e-9) { axis = scl(axisRaw, 1 / s); theta = Math.atan2(s, e[2]); }
+  else if (e[2] < 0) { axis = [1, 0, 0]; theta = Math.PI; }
+  const u = axis ? rotVec([1, 0, 0], axis, theta) : [1, 0, 0];
+  const v = axis ? rotVec([0, 1, 0], axis, theta) : [0, 1, 0];
+  const p2 = (w) => [dot(w, u), dot(w, v)];
+  const poly = profile2D({ P: [0, 0], n1: p2(n1), n2: p2(n2), magnitude, mode, convex, segs });
+  // convex cutters overshoot the edge ends (sticking outside the solid is
+  // harmless when subtracting); concave fillers must end flush — any overshoot
+  // would bulge outside the part when unioned
+  const over = convex ? Math.max(1e-3, 0.05 * magnitude) : 0;
+  let tool = k.loft(
+    [{ polygon: poly, z: -over }, { polygon: poly, z: length + over }],
+    { shading: "smooth" },
+  );
+  if (axis) tool = tool.rotateAbout({ axis, deg: (theta * 180) / Math.PI });
+  return tool.translate(a);
+}
+
+function revolveTool(k, chain, magnitude, mode, segs) {
+  const { O, w, u0, v0, R, span, closed, n1, n2, convex } = chain;
+  // Seam-grazing guard. The edge circle passes through the flank tessellation's
+  // VERTICES (circumradius) while its facets sit at the apothem, so a revolved
+  // tool built exactly at R grazes every facet seam tangentially — Manifold
+  // keeps the resulting epsilon-degenerate needle triangles, and simplify()
+  // cannot always collapse them. `sag` is that facet sagitta plus a roundoff pad
+  // bounded relative to the requested feature, so tiny blends never inherit a
+  // fixed allowance larger than their own cross-section.
+  const sag = (R + magnitude) * (1 - Math.cos(Math.PI / segs)) + Math.min(2e-4, 0.02 * magnitude);
+  // Fillet: size the arc-tail extension to cross the facet planes, but cap it at
+  // 0.4 rad. Below the mesh's own facet scale a larger tail wraps around the tiny
+  // profile and creates one tunnel per facet; the cap bounds penetration to 8%
+  // of the requested radius while the cutter's outside corner still opens into
+  // free space.
+  const ext = Math.min(0.4, Math.max(0.01, Math.acos(Math.max(-1, 1 - sag / magnitude))));
+  let poly = profile2D({ P: [R, 0], n1, n2, magnitude, mode, convex, segs, ext });
+  if (mode === "chamfer") {
+    // Chamfer: the cone itself is the cutting surface — no tail to extend, so
+    // bury the whole profile by `sag` along the material-side bisector instead.
+    // The chamfer lands microns deep; dimensionally invisible.
+    const bl2 = Math.hypot(n1[0] + n2[0], n1[1] + n2[1]);
+    const bis2 = [(n1[0] + n2[0]) / bl2, (n1[1] + n2[1]) / bl2];
+    // A convex cutter must leave its outside closure corner unburied: moving the
+    // whole profile inward can close a micro-tunnel per flank facet when sag is
+    // larger than a tiny chamfer. A concave filler needs every point buried so
+    // it overlaps the source solid instead of leaving disconnected components.
+    poly = poly.map(([x, y], i) => i === 0 && convex ? [x, y] : [x - sag * bis2[0], y - sag * bis2[1]]);
+  }
+  if (poly.some(([x]) => x <= 0)) throw new UnsupportedEdgeError("fillet crosses the revolve axis (radius too large for this bore)");
+  // enforce CCW winding for the revolve
+  let area = 0;
+  for (let i = 0; i < poly.length; i++) {
+    const [x1, y1] = poly[i], [x2, y2] = poly[(i + 1) % poly.length];
+    area += x1 * y2 - x2 * y1;
+  }
+  if (area < 0) poly = poly.slice().reverse();
+  const ovAng = closed || !convex ? 0 : Math.min(0.15, Math.max(1e-3, (0.05 * magnitude) / R));
+  const degrees = closed ? 360 : ((span + 2 * ovAng) * 180) / Math.PI;
+  let tool = k.revolve(poly, { degrees });
+  // pose: Z → w, then twist so the revolve's start azimuth (+X) lands on the
+  // chain's start direction (backed off by the angular overshoot)
+  const startDir = closed ? u0 : add(scl(u0, Math.cos(-ovAng)), scl(v0, Math.sin(-ovAng)));
+  const axisRaw = cross([0, 0, 1], w);
+  const s = len(axisRaw);
+  let axis = null, theta = 0;
+  if (s > 1e-9) { axis = scl(axisRaw, 1 / s); theta = Math.atan2(s, w[2]); }
+  else if (w[2] < 0) { axis = [1, 0, 0]; theta = Math.PI; }
+  if (axis) tool = tool.rotateAbout({ axis, deg: (theta * 180) / Math.PI });
+  const xImage = axis ? rotVec([1, 0, 0], axis, theta) : [1, 0, 0];
+  // Closed revolves get an extra half-facet twist: at 360° the tool's facet
+  // pitch exactly matches the flank's, and phase-aligned seams graze vertex-on-
+  // vertex at every step (the degenerate-needle generator). Half a step lands
+  // every crossing mid-facet. Partial arcs have a slightly different pitch
+  // (degrees don't divide evenly) and never align in the first place.
+  const dephase = closed ? Math.PI / segs : 0;
+  const twist = Math.atan2(dot(w, cross(xImage, startDir)), dot(xImage, startDir)) + dephase;
+  if (Math.abs(twist) > 1e-9) tool = tool.rotateAbout({ axis: w, deg: (twist * 180) / Math.PI });
+  return tool.translate(O);
+}
+
+// ---------------------------------------------------------------------------
+// Spherical corner patches. Where exactly three selected straight convex chains
+// meet at a vertex with mutually orthogonal directions (a box-like corner), the
+// three edge blends are capped with a rolling-ball sphere octant instead of the
+// default mitre: cutter = corner cube − sphere(C, r), the classic corner-mask
+// construction, with C = V + r·(ê1+ê2+ê3) (distance r inside each face). The
+// cube spans exactly [V, V + r·ê_j] — the sphere-cylinder tangent planes —
+// because inside that cube the true rolling-ball surface is PURE sphere (the
+// edge cylinders end at the tangent planes; extending protection cylinders in
+// here would preserve their proud Steinmetz-intersection ridges instead of the
+// sphere patch, and extending the cube out would gouge the edge fillets). The
+// cube's outer walls land inside the material the edge cutters already remove,
+// so the only new surface is the octant. Non-orthogonal corners keep the mitre
+// — the safe, documented default.
+function cornerPatches(k, selected, r, segs) {
+  const lines = selected.filter((ch) => ch.kind === "line" && ch.convex);
+  const byVertex = new Map();
+  for (const ch of lines) {
+    for (const [pt, dirOut] of [[ch.a, ch.dir], [ch.b, scl(ch.dir, -1)]]) {
+      const key = pt.map((v) => Math.round(v * 1e4)).join(",");
+      (byVertex.get(key) ?? byVertex.set(key, []).get(key)).push({ pt, dirOut });
+    }
+  }
+  const patches = [];
+  for (const ends of byVertex.values()) {
+    if (ends.length !== 3) continue;
+    let [e1, e2, e3] = ends.map((e) => e.dirOut);
+    const ortho = Math.abs(dot(e1, e2)) < 1e-3 && Math.abs(dot(e1, e3)) < 1e-3 && Math.abs(dot(e2, e3)) < 1e-3;
+    if (!ortho) continue; // non-orthogonal trihedral: leave the mitre
+    if (dot(cross(e1, e2), e3) < 0) [e2, e3] = [e3, e2]; // right-handed frame
+    const V = ends[0].pt;
+    const C = add(V, scl(add(add(e1, e2), e3), r));
+    const dOut = 0.02 * r;
+    // Bury the sphere a hair into the material (past its own facet sagitta): it
+    // is tangent to each flat face at a point and meets the edge-fillet
+    // cylinders tangentially at the cube walls, and tessellated tangency
+    // produces the same grazing-noise creases the edge tools guard against.
+    const bury = r * (1 - Math.cos(Math.PI / segs)) + 1e-3;
+    const inward = norm(add(add(e1, e2), e3));
+    // corner block: cube spanned by the edge frame, oversized only outward
+    let block = k.box({ min: [-dOut, -dOut, -dOut], max: [r, r, r] });
+    // pose standard axes onto (e2, e3, e1): Z → e1, then twist X-image onto e2
+    const axisRaw = cross([0, 0, 1], e1);
+    const s = len(axisRaw);
+    let axis = null, theta = 0;
+    if (s > 1e-9) { axis = scl(axisRaw, 1 / s); theta = Math.atan2(s, e1[2]); }
+    else if (e1[2] < 0) { axis = [1, 0, 0]; theta = Math.PI; }
+    if (axis) block = block.rotateAbout({ axis, deg: (theta * 180) / Math.PI });
+    const xImage = axis ? rotVec([1, 0, 0], axis, theta) : [1, 0, 0];
+    const twist = Math.atan2(dot(e1, cross(xImage, e2)), dot(xImage, e2));
+    if (Math.abs(twist) > 1e-9) block = block.rotateAbout({ axis: e1, deg: (twist * 180) / Math.PI });
+    block = block.translate(V);
+    patches.push(block.cut(k.sphere({ r }).at(add(C, scl(inward, bury)))));
+  }
+  return patches;
+}
+
+// ---------------------------------------------------------------------------
+// Entry points.
+//   meshFillet(k, solid, { r, edges?, segs?, sharpDeg? })  → Solid
+//   meshChamfer(k, solid, { d, edges?, segs?, sharpDeg? }) → Solid
+export function meshFillet(k, solid, opts) { return apply(k, solid, "fillet", opts?.r, opts); }
+export function meshChamfer(k, solid, opts) { return apply(k, solid, "chamfer", opts?.d, opts); }
+
+function apply(k, solid, mode, magnitude, { edges, segs = DEFAULT_SEGS, sharpDeg = 20 } = {}) {
+  if (!(magnitude > 0)) throw new Error(`mesh ${mode}: magnitude must be > 0`);
+  const chains = chainEdges(detectSharpEdges(solid.toIndexedMesh(), { sharpDeg }));
+  const selected = chains.filter((ch) => matchesSelector(ch, edges));
+  if (!selected.length) throw new UnsupportedEdgeError(`${mode} selector matched no sharp edges`);
+  const unsupported = selected.find((ch) => ch.kind === "unsupported");
+  if (unsupported) throw new UnsupportedEdgeError(`${mode}: ${unsupported.reason}`);
+  const tool = (ch) => (ch.kind === "arc" ? revolveTool : prismTool)(k, ch, magnitude, mode, segs);
+  const cutters = selected.filter((ch) => ch.convex).map(tool);
+  const fillers = selected.filter((ch) => !ch.convex).map(tool);
+  if (mode === "fillet") cutters.push(...cornerPatches(k, selected, magnitude, segs));
+  let out = solid;
+  if (cutters.length) out = out.cutAll(cutters);
+  if (fillers.length) out = k.union([out, ...fillers]);
+  return out;
+}

package/src/framework/geometry/probe.js

@@ -1,7 +1,7 @@
 // Geometry-free build execution. Two consumers share one Proxy implementation:
 //
 //  • createProbeKernel() — records op NAMES so ../backend-select.js's
-//    detectBackend() can route a part to OCCT when it uses fillet/chamfer/shell.
+//    detectBackend() can route a part to OCCT when it uses Solid.shell.
 //  • createValidatingProbe() — additionally checks op names against the kernel
 //    contract's op lists and routes options-form calls through the same op-options
 //    normalizers the real backends use, so partforge/lint can catch a bad call in
@@ -15,17 +15,17 @@
 // lists, which test/kernel-contract.test.js pins to both backend implementations.
 import {
   KERNEL_OPS, KERNEL_OPTIONAL_OPS,
-  SOLID_OPS, SOLID_OPTIONAL_OPS, SHAPE2D_OPS, OCCT_ONLY_OPS,
+  SOLID_OPS, SOLID_OPTIONAL_OPS, SHAPE2D_OPS, ROUTED_CAD_OPS,
 } from "./kernel.js";
 import { KERNEL_OP_SPECS, SOLID_OP_SPECS, isPlainOptions } from "./op-options.js";
 
 // The probe hands out TWO chainable handles: k.shape2d()/k.text2d() yield a Shape2D
 // handle (whose extrude/revolve yield the Solid handle), everything else yields the
-// Solid handle. The split exists for one reason — backend routing: `Shape2D.fillet`
-// is the shared pure-JS implementation and must NOT route a part to OCCT, while
-// `Solid.fillet` must. Handle-level VALIDATION stays deliberately permissive (one
-// union allowlist for both handle kinds), so the split can never false-positive on
-// an error-severity rule.
+// Solid handle. The split lets lint and routing distinguish handle-specific ops:
+// `Shape2D.fillet` is shared pure JS, `Solid.fillet` starts mesh-native and may
+// request a runtime OCCT fallback, and `Solid.shell` probe-routes up front.
+// Handle-level VALIDATION stays deliberately permissive (one union allowlist for
+// both handle kinds), so the split can never false-positive on an error rule.
 const KERNEL_ALLOWED = new Set([...KERNEL_OPS, ...KERNEL_OPTIONAL_OPS]);
 const SOLID_ALLOWED = new Set([...SOLID_OPS, ...SOLID_OPTIONAL_OPS, ...SHAPE2D_OPS]);
 
@@ -92,14 +92,13 @@ function makeProbe(onCall) {
   return { kernel, proxy, shape2d };
 }
 
-const CAD_OPS = new Set(OCCT_ONLY_OPS);
+const CAD_OPS = new Set(ROUTED_CAD_OPS);
 
 export function createProbeKernel() {
   const used = new Set();       // every op name, any handle kind
   const solidUsed = new Set();  // ops recorded on kernel/Solid handles only — the
                                 // routing set: Shape2D.fillet must not look like Solid.fillet
-  const cadCalls = [];          // Solid-handle fillet/chamfer/shell calls WITH args —
-                                // routing needs the magnitude (fillet(0) is identity, stays on Manifold)
+  const cadCalls = [];          // Probe-routed Solid ops WITH args (currently shell).
   const { kernel } = makeProbe((scope, key, args) => {
     used.add(key);
     if (scope !== "shape2d") {

package/src/framework/lint/rules-build.js

@@ -2,10 +2,12 @@
 // the validating probe with no geometry kernel. Every error in this group already
 // throws at runtime; the value is reaching it in microseconds, before a WASM boot.
 import { err, warn } from "./finding.js";
-import { OCCT_ONLY_OPS } from "../geometry/kernel.js";
+import { ROUTED_CAD_OPS } from "../geometry/kernel.js";
 import { MAX_PROBE_OPS } from "../geometry/probe.js";
 
-const OCCT_ONLY = new Set(OCCT_ONLY_OPS);
+// fillet/chamfer are implemented on the mesh backend now (mesh-fillet.js), so a
+// pinned-Manifold part may use them; only the still-unimplemented ops error here.
+const OCCT_ONLY = new Set(ROUTED_CAD_OPS);
 const unique = (xs) => [...new Set(xs)];
 
 export const BUILD_RULES = [
@@ -52,9 +54,8 @@ export const BUILD_RULES = [
     id: "manifold-backend-uses-occt-op",
     run: ({ part, probe }) => {
       if (part?.meta?.backend !== "manifold") return [];
-      // solidUsed, not used: `Shape2D.fillet`/`.chamfer` are backend-identical pure
-      // JS and are fine under a pinned Manifold backend; only Solid-handle uses of
-      // these names are CAD-only.
+      // solidUsed, not used: a Shape2D method with the same name as a routed Solid
+      // op is still backend-identical pure JS and is fine under pinned Manifold.
       return [...probe().solidUsed].filter((op) => OCCT_ONLY.has(op))
         .map((op) => err("manifold-backend-uses-occt-op",
           `\`meta.backend\` pins Manifold, but the build calls \`${op}\`, which only OCCT implements`,