M7b: thicken-from-surface + surface offset

Two features bridging sheet bodies back to solids and to other sheets:
ThickenSurface feeds a whole sheet shell to MakeThickSolidBySimple (the same
OCCT recipe the face-level Thicken already uses) and appends the result as a
solid; SurfaceOffset offsets a sheet's shell along its normals via
MakeOffsetShape::PerformBySimple, keeping it open. Both refuse a non-sheet
target with a clear error.

Purely additive: two enum values appended to CadFeatureType, reusing the
existing target_body / thicken_thickness / thicken_flip / plane_offset
fields. No new cereal fields, recipe stays v2, golden fixture unchanged
(30773). MCP thicken_surface/surface_offset added as pure additions.
Suite 103 cases / 1520 assertions green.

Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01BVzKmX6Y1aEteit1HTXG4Q

src/libslic3r/CadDocument.cpp

@@ -18,6 +18,7 @@
 #include <BRepOffsetAPI_MakePipe.hxx>
 #include <BRepOffsetAPI_MakePipeShell.hxx>
 #include <BRepOffsetAPI_MakeThickSolid.hxx>
+#include <BRepOffsetAPI_MakeOffsetShape.hxx>
 #include <BRepOffsetAPI_DraftAngle.hxx>
 #include <Bnd_Box.hxx>
 #include <BRepBndLib.hxx>
@@ -1197,6 +1198,32 @@ int CadDocument::add_thicken(int target_body, int face, double thickness, bool f
     return int(features.size()) - 1;
 }
 
+int CadDocument::add_thicken_surface(int target_body, double thickness, bool flip,
+                                      const std::string& name)
+{
+    CadFeature f;
+    f.type              = CadFeatureType::ThickenSurface;
+    f.name              = name;
+    f.target_body       = target_body;
+    f.thicken_thickness = thickness;
+    f.thicken_flip      = flip;
+    f.mode              = BooleanMode::New;
+    features.push_back(f);
+    return int(features.size()) - 1;
+}
+
+int CadDocument::add_surface_offset(int target_body, double offset, const std::string& name)
+{
+    CadFeature f;
+    f.type         = CadFeatureType::SurfaceOffset;
+    f.name         = name;
+    f.target_body  = target_body;
+    f.plane_offset = offset;
+    f.mode         = BooleanMode::New;
+    features.push_back(f);
+    return int(features.size()) - 1;
+}
+
 int CadDocument::add_project_edges(int source_body, const std::vector<int>& edge_ids, int face,
                                    const SketchPlane& plane, const std::string& name)
 {
@@ -2672,6 +2699,52 @@ void CadDocument::apply_thicken(std::vector<CadBody>& bodies, const CadFeature&
     bodies.push_back({solid, f.name.empty() ? std::string("Thicken") : f.name});
 }
 
+void CadDocument::apply_thicken_surface(std::vector<CadBody>& bodies, const CadFeature& f) const
+{
+    const int nb = int(bodies.size());
+    if (nb == 0) throw std::runtime_error("thicken-surface: no target body");
+    const int tgt = (f.target_body >= 0 && f.target_body < nb) ? f.target_body : nb - 1;
+    if (tgt < 0 || bodies[tgt].shape.IsNull()) throw std::runtime_error("thicken-surface: no target body");
+    if (!is_sheet_shape(bodies[tgt].shape)) throw std::runtime_error("thicken-surface: target is not a sheet body");
+    if (std::abs(f.thicken_thickness) < 1e-9) throw std::runtime_error("thicken-surface: thickness is zero");
+
+    const double off = f.thicken_flip ? -std::abs(f.thicken_thickness)
+                                      :  std::abs(f.thicken_thickness);
+    BRepOffsetAPI_MakeThickSolid mts;
+    mts.MakeThickSolidBySimple(bodies[tgt].shape, off);
+    mts.Build();
+    if (!mts.IsDone()) throw std::runtime_error("thicken-surface: failed");
+    TopoDS_Shape solid = mts.Shape();
+    if (solid.IsNull()) throw std::runtime_error("thicken-surface: produced no geometry");
+
+    {
+        GProp_GProps props;
+        BRepGProp::VolumeProperties(solid, props);
+        if (props.Mass() < 0.0) solid.Reverse();
+    }
+
+    bodies.push_back({solid, f.name.empty() ? std::string("ThickenSurface") : f.name});
+}
+
+void CadDocument::apply_surface_offset(std::vector<CadBody>& bodies, const CadFeature& f) const
+{
+    const int nb = int(bodies.size());
+    if (nb == 0) throw std::runtime_error("surface-offset: no target body");
+    const int tgt = (f.target_body >= 0 && f.target_body < nb) ? f.target_body : nb - 1;
+    if (tgt < 0 || bodies[tgt].shape.IsNull()) throw std::runtime_error("surface-offset: no target body");
+    if (!is_sheet_shape(bodies[tgt].shape)) throw std::runtime_error("surface-offset: target is not a sheet body");
+    const double d = f.plane_offset;
+    if (std::abs(d) < 1e-9) throw std::runtime_error("surface-offset: zero offset");
+
+    BRepOffsetAPI_MakeOffsetShape mos;
+    mos.PerformBySimple(bodies[tgt].shape, d);
+    if (!mos.IsDone()) throw std::runtime_error("surface-offset: failed");
+    TopoDS_Shape off_shape = mos.Shape();
+    if (off_shape.IsNull()) throw std::runtime_error("surface-offset: produced no geometry");
+
+    bodies.push_back({off_shape, f.name.empty() ? std::string("SurfaceOffset") : f.name});
+}
+
 void CadDocument::apply_project(const std::vector<CadBody>& bodies, CadFeature& f) const
 {
     f.entities.clear();
@@ -2769,6 +2842,8 @@ void CadDocument::route_feature(std::vector<CadBody>& bodies, const CadFeature&
     if (f.type == CadFeatureType::Mirror)  { apply_mirror(bodies, f);  return; }   // mirror body about plane
     if (f.type == CadFeatureType::Transform) { apply_transform(bodies, f); return; }   // move/rotate body
     if (f.type == CadFeatureType::Thicken) { apply_thicken(bodies, f); return; }   // face -> plate
+    if (f.type == CadFeatureType::ThickenSurface) { apply_thicken_surface(bodies, f); return; }
+    if (f.type == CadFeatureType::SurfaceOffset) { apply_surface_offset(bodies, f); return; }
     if (f.type == CadFeatureType::Project) return;   // sketch-like: consumed downstream, no body
     // Resolve the target body: explicit target_body when valid, else the last body.
     const int t = (f.target_body >= 0 && f.target_body < int(bodies.size()))
@@ -2779,6 +2854,7 @@ void CadDocument::route_feature(std::vector<CadBody>& bodies, const CadFeature&
     const bool starts_new = bodies.empty()
         || f.type == CadFeatureType::Import   // an imported solid is always its own base body
         || f.type == CadFeatureType::SurfaceExtrude || f.type == CadFeatureType::SurfaceRevolve
+        || f.type == CadFeatureType::ThickenSurface || f.type == CadFeatureType::SurfaceOffset
         || ((f.type == CadFeatureType::Extrude || f.type == CadFeatureType::Revolve
              || f.type == CadFeatureType::Sweep || f.type == CadFeatureType::Loft)
             && f.mode == BooleanMode::New);

src/libslic3r/CadDocument.hpp

@@ -19,7 +19,7 @@
 
 namespace Slic3r {
 
-enum class CadFeatureType { Sketch, Extrude, Fillet, Chamfer, Hole, Thread, Shell, Revolve, Sweep, Pattern, Plane, Loft, Draft, Import, Boolean, Cut, Mirror, Axis, CoordSys, Helix, Transform, Thicken, Project, DeleteFace, Rib, SurfaceExtrude, SurfaceRevolve };
+enum class CadFeatureType { Sketch, Extrude, Fillet, Chamfer, Hole, Thread, Shell, Revolve, Sweep, Pattern, Plane, Loft, Draft, Import, Boolean, Cut, Mirror, Axis, CoordSys, Helix, Transform, Thicken, Project, DeleteFace, Rib, SurfaceExtrude, SurfaceRevolve, ThickenSurface, SurfaceOffset };
 enum class SketchShape    { Rectangle, Circle };
 enum class PlaneType      { Offset, Angle, Midplane, Tangent, TwoEdges, Coincident };
 enum class AxisType       { TwoPoints, FaceNormal, CylinderCenterline, PlaneIntersection, AlongEdge };
@@ -508,6 +508,10 @@ public:
     // Offset face `face` of `target_body` by `thickness` along its normal, producing a new
     // thin solid appended as a new body. flip=true offsets against the normal.
     int add_thicken(int target_body, int face, double thickness, bool flip, const std::string& name);
+    // Thicken an entire SHEET body's shell into a solid.
+    int add_thicken_surface(int target_body, double thickness, bool flip, const std::string& name);
+    // Offset a SHEET body's shell by a signed distance, producing another SHEET body.
+    int add_surface_offset(int target_body, double offset, const std::string& name);
     int add_delete_face(int target_body, const std::vector<int>& faces,
                         const std::string& name);
     int add_surface_extrude(int sketch_ref, double distance, const std::string& name);
@@ -623,6 +627,8 @@ private:
     void apply_mirror(std::vector<CadBody>& bodies, const CadFeature& f) const;
     void apply_transform(std::vector<CadBody>& bodies, const CadFeature& f) const;
     void apply_thicken(std::vector<CadBody>& bodies, const CadFeature& f) const;
+    void apply_thicken_surface(std::vector<CadBody>& bodies, const CadFeature& f) const;
+    void apply_surface_offset(std::vector<CadBody>& bodies, const CadFeature& f) const;
     void apply_project(const std::vector<CadBody>& bodies, CadFeature& f) const;
 
     // Undo/redo stacks of feature-list snapshots. checkpoint() pushes onto m_undo and

src/slic3r/GUI/McpControl.cpp

@@ -1041,6 +1041,35 @@ json action_surface_revolve(DesignPanel* panel, const json& params)
     return json{{"ok", ok}, {"feature_index", idx}, {"bodies", int(doc.bodies.size())}, {"error", doc.error}};
 }
 
+json action_thicken_surface(DesignPanel* panel, const json& params)
+{
+    CadDocument& doc = panel->mcp_doc();
+    if (doc.bodies.empty()) throw std::runtime_error("no sheet body to thicken");
+    int bi = target_body_arg(params, doc);
+    double thickness = params.value("thickness", 2.0);
+    bool flip = params.value("flip", false);
+    doc.checkpoint();
+    int idx = doc.add_thicken_surface(bi, thickness, flip, "ThickenSurface");
+    bool ok = doc.recompute();
+    if (!ok) doc.undo();
+    panel->mcp_after_change();
+    return json{{"ok", ok}, {"feature_index", idx}, {"bodies", int(doc.bodies.size())}, {"error", doc.error}};
+}
+
+json action_surface_offset(DesignPanel* panel, const json& params)
+{
+    CadDocument& doc = panel->mcp_doc();
+    if (doc.bodies.empty()) throw std::runtime_error("no sheet body to offset");
+    int bi = target_body_arg(params, doc);
+    double offset = params.value("offset", 1.0);
+    doc.checkpoint();
+    int idx = doc.add_surface_offset(bi, offset, "SurfaceOffset");
+    bool ok = doc.recompute();
+    if (!ok) doc.undo();
+    panel->mcp_after_change();
+    return json{{"ok", ok}, {"feature_index", idx}, {"bodies", int(doc.bodies.size())}, {"error", doc.error}};
+}
+
 json action_draft(DesignPanel* panel, const json& params)
 {
     if (!params.contains("face")) throw std::runtime_error("draft needs 'face' (id from query_topology)");
@@ -1332,6 +1361,8 @@ std::string handle_on_main(const std::string& method, const json& params, const
         if (method == "set_feature_expr") return rpc_result(id, action_set_feature_expr(panel, params));
         if (method == "surface_extrude")  return rpc_result(id, action_surface_extrude(panel, params));
         if (method == "surface_revolve")  return rpc_result(id, action_surface_revolve(panel, params));
+        if (method == "thicken_surface")  return rpc_result(id, action_thicken_surface(panel, params));
+        if (method == "surface_offset")   return rpc_result(id, action_surface_offset(panel, params));
         return rpc_error(id, -32601, "Unknown method: " + method);
     } catch (const Standard_Failure& ex) {   // OCCT errors are NOT std::exception
         return rpc_error(id, -32000, std::string("OCCT: ") + (ex.GetMessageString() ? ex.GetMessageString() : "failure"));

tests/libslic3r/test_caddocument.cpp

@@ -4626,3 +4626,129 @@ TEST_CASE("surface round-trip serialize/deserialize", "[CadDocument][surface]")
     REQUIRE_THAT(double(fy1), WithinAbs(double(oy1), 1e-6));
     REQUIRE_THAT(double(fz1), WithinAbs(double(oz1), 1e-6));
 }
+
+TEST_CASE("thicken-surface makes a solid from a sheet", "[CadDocument][surface]")
+{
+    using Catch::Matchers::WithinRel;
+    using Catch::Matchers::WithinAbs;
+
+    CadDocument doc;
+    int sk = doc.add_sketch(SketchShape::Rectangle, SketchPlane::XY(), 20, 20, 0, "Rect");
+    REQUIRE(sk >= 0);
+    int si = doc.add_surface_extrude(sk, 12.0, "Skin");
+    REQUIRE(doc.recompute());
+    REQUIRE(doc.error.empty());
+    REQUIRE(doc.bodies.size() == 1);
+    REQUIRE(CadDocument::is_sheet_shape(doc.bodies.back().shape));
+
+    Bnd_Box sheet_bb;
+    BRepBndLib::Add(doc.bodies.back().shape, sheet_bb);
+
+    int ti = doc.add_thicken_surface(0, 2.0, false, "Wall");
+    REQUIRE(ti == 2);
+    REQUIRE(doc.recompute());
+    REQUIRE(doc.error.empty());
+    REQUIRE(doc.bodies.size() == 2);
+
+    REQUIRE(!CadDocument::is_sheet_shape(doc.bodies.back().shape));
+    double vol = doc.body_mass_properties(1).volume;
+    REQUIRE(vol > 0);
+
+    Bnd_Box thick_bb;
+    BRepBndLib::Add(doc.bodies.back().shape, thick_bb);
+    Standard_Real sx0, sy0, sz0, sx1, sy1, sz1;
+    Standard_Real tx0, ty0, tz0, tx1, ty1, tz1;
+    sheet_bb.Get(sx0, sy0, sz0, sx1, sy1, sz1);
+    thick_bb.Get(tx0, ty0, tz0, tx1, ty1, tz1);
+    REQUIRE_THAT(double(tx0), WithinAbs(double(sx0), 2.1));
+    REQUIRE_THAT(double(tx1), WithinAbs(double(sx1), 2.1));
+}
+
+TEST_CASE("surface-offset creates another sheet shifted outward", "[CadDocument][surface]")
+{
+    using Catch::Matchers::WithinAbs;
+
+    CadDocument doc;
+    int sk = doc.add_sketch(SketchShape::Rectangle, SketchPlane::XY(), 20, 20, 0, "Rect");
+    REQUIRE(sk >= 0);
+    int si = doc.add_surface_extrude(sk, 12.0, "Skin");
+    REQUIRE(doc.recompute());
+    REQUIRE(doc.error.empty());
+
+    Bnd_Box src_bb;
+    BRepBndLib::Add(doc.bodies.back().shape, src_bb);
+
+    int oi = doc.add_surface_offset(0, 1.0, "Off");
+    REQUIRE(oi == 2);
+    REQUIRE(doc.recompute());
+    REQUIRE(doc.error.empty());
+    REQUIRE(doc.bodies.size() == 2);
+    REQUIRE(CadDocument::is_sheet_shape(doc.bodies.back().shape));
+
+    Bnd_Box off_bb;
+    BRepBndLib::Add(doc.bodies.back().shape, off_bb);
+    Standard_Real sx0, sy0, sz0, sx1, sy1, sz1;
+    Standard_Real ox0, oy0, oz0, ox1, oy1, oz1;
+    src_bb.Get(sx0, sy0, sz0, sx1, sy1, sz1);
+    off_bb.Get(ox0, oy0, oz0, ox1, oy1, oz1);
+    REQUIRE(std::abs(double(ox0) - double(sx0)) > 1e-3);
+    REQUIRE(std::abs(double(ox1) - double(sx1)) > 1e-3);
+    REQUIRE(std::abs(double(oy0) - double(sy0)) > 1e-3);
+    REQUIRE(std::abs(double(oy1) - double(sy1)) > 1e-3);
+}
+
+TEST_CASE("thicken-surface on non-sheet fails", "[CadDocument][surface]")
+{
+    CadDocument doc;
+    int sk = doc.add_sketch(SketchShape::Rectangle, SketchPlane::XY(), 20, 20, 0, "Rect");
+    REQUIRE(sk >= 0);
+    doc.add_extrude(sk, 10.0, false, BooleanMode::New, "Solid");
+    REQUIRE(doc.recompute());
+    REQUIRE(doc.error.empty());
+    REQUIRE_FALSE(CadDocument::is_sheet_shape(doc.bodies.back().shape));
+
+    doc.add_thicken_surface(0, 2.0, false, "Bad");
+    REQUIRE_FALSE(doc.recompute());
+    REQUIRE_THAT(doc.error, Catch::Matchers::Contains("sheet"));
+}
+
+TEST_CASE("thicken-surface round-trip serialize/deserialize", "[CadDocument][surface]")
+{
+    using Catch::Matchers::WithinAbs;
+    using Catch::Matchers::WithinRel;
+
+    CadDocument doc;
+    int sk = doc.add_sketch(SketchShape::Rectangle, SketchPlane::XY(), 20, 20, 0, "Rect");
+    doc.add_surface_extrude(sk, 12.0, "Skin");
+    REQUIRE(doc.recompute());
+    doc.add_thicken_surface(0, 2.0, false, "Wall");
+    REQUIRE(doc.recompute());
+    REQUIRE(doc.error.empty());
+    REQUIRE_FALSE(CadDocument::is_sheet_shape(doc.bodies.back().shape));
+
+    size_t orig_nb = doc.bodies.size();
+    Bnd_Box orig_bb;
+    BRepBndLib::Add(doc.bodies.back().shape, orig_bb);
+
+    std::string blob = doc.serialize_recipe();
+    REQUIRE_FALSE(blob.empty());
+
+    CadDocument fresh;
+    REQUIRE(fresh.deserialize_recipe(blob));
+    REQUIRE(fresh.error.empty());
+    REQUIRE(fresh.bodies.size() == orig_nb);
+    REQUIRE_FALSE(CadDocument::is_sheet_shape(fresh.bodies.back().shape));
+
+    Bnd_Box fresh_bb;
+    BRepBndLib::Add(fresh.bodies.back().shape, fresh_bb);
+    Standard_Real ox0, oy0, oz0, ox1, oy1, oz1;
+    Standard_Real fx0, fy0, fz0, fx1, fy1, fz1;
+    orig_bb.Get(ox0, oy0, oz0, ox1, oy1, oz1);
+    fresh_bb.Get(fx0, fy0, fz0, fx1, fy1, fz1);
+    REQUIRE_THAT(double(fx0), WithinAbs(double(ox0), 1e-6));
+    REQUIRE_THAT(double(fy0), WithinAbs(double(oy0), 1e-6));
+    REQUIRE_THAT(double(fz0), WithinAbs(double(oz0), 1e-6));
+    REQUIRE_THAT(double(fx1), WithinAbs(double(ox1), 1e-6));
+    REQUIRE_THAT(double(fy1), WithinAbs(double(oy1), 1e-6));
+    REQUIRE_THAT(double(fz1), WithinAbs(double(oz1), 1e-6));
+}