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A stray click must not break a model that looks perfect on screen

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Revolve failed on a sketch whose profile was closed. Decoding the reported 3mf: four
entities forming a proper closed loop (joints open by 4.44e-06 mm, well inside
tolerance) plus one stray 1.82 mm Line at (-24.2, 80.3), inside the shaded region,
touching nothing.

The viewport's region_loops discards open chains ON PURPOSE — it exists to find
EXTRUDABLE regions — so the user saw one clean closed region. entities_to_wires kept
the stray as its own one-edge loop, so it returned two wires, and Revolve goes through
entities_to_wire which demands exactly one. Extrude would have failed one step later in
wires_to_face, because a one-edge open wire bounds no face. Same class as the tolerance
split fixed in 8b568b7b: the viewport and the kernel disagreeing about the sketch — this
time about what BELONGS to the profile.

entities_to_wires/entities_to_wire/build_sketch_wire take closed_only. It is not a
blanket rule: a SurfaceExtrude builds a sheet FROM an open profile and a Sweep PATH is
normally open, so all ten call sites are classified individually — true for the face
fallback, Extrude-taper, Revolve, the Sweep PROFILE and Loft profiles; false for
SurfaceExtrude/Revolve/Loft/Fill and the Sweep path.

A component counts as open when some welded node has DEGREE 1. The first attempt used
"the traversal did not return to its starting node", which regressed the bridged C
profile: a closed loop that also carries a second edge across the same two nodes has no
free endpoint, but its Eulerian walk ends elsewhere. Degree-1 is the property that
actually distinguishes a stray segment from a closed profile; the suite caught the
difference.

Behaviour change decided by Tommaso: a stray is IGNORED, not refused. The test that
required refusal dates from when ignoring meant falling through to a default rectangle —
geometry nobody drew. That fallback is gone, so ignoring now builds the circle the user
actually drew. Its assertion is updated with the reason.

The bridge round-trip test extruded an ENTIRELY open chain and "worked" only because
OCCT will make a face from an open wire. It gets a genuinely closed profile: the test is
about serialization, and deserialize_recipe recomputes, so the document has to be one
that legitimately builds.

Failures now say WHERE. sketch_open_ends reports free endpoints under the same weld
tolerance the wire build uses, and open_loop_message is shared by both throws, because
Extrude fails through build_sketch_face and Revolve through build_sketch_wire — enriching
only one would have left the commoner path the less informative one.

Kernel 66115 assertions / 608 cases green.

Co-Authored-By: Claude Opus 5 (1M context) <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_011FbJKJAJxxkhDTs9XdZzKA
This commit is contained in:
Tommaso Bianchi
2026-09-02 14:58:05 +02:00
co-authored by Claude Opus 5
parent 8b568b7b9d
commit bb6a1810f6
6 changed files with 231 additions and 32 deletions
Download Patch File Download Diff File Expand all files Collapse all files
src/libslic3r/CAD/CadDocument.cpp
+40 -12
View File
@@ -68,6 +68,7 @@
#include <GProp_GProps.hxx>
#include <cmath>
#include <cctype>
#include <cstdio>
#include <stdexcept>
#include <algorithm>
#include <sstream>
@@ -2109,10 +2110,33 @@ bool CadDocument::replace_sketch_extrude(int sketch_idx, int extrude_idx,
return commit_or_rollback(*this, snapshot);
}
TopoDS_Wire CadDocument::build_sketch_wire(const CadFeature& sketch) const
// "the sketch is open" is not actionable; WHERE it is open is. Shared by both throws so the
// two ways of reaching an open profile (Revolve via build_sketch_wire, Extrude via
// build_sketch_face) report it identically.
static std::string open_loop_message(const CadFeature& sketch,
const char* head = "sketch entities do not form a closed loop")
{
std::string msg = head;
const std::vector<Vec2d> open = Slic3r::sketch_open_ends(sketch.entities, sketch.plane);
if (!open.empty()) {
const size_t shown = std::min<size_t>(open.size(), 3);
char buf[96];
for (size_t i = 0; i < shown; ++i) {
std::snprintf(buf, sizeof buf, "\n Open at (%.3f, %.3f)", open[i].x(), open[i].y());
msg += buf;
}
if (open.size() > shown) {
std::snprintf(buf, sizeof buf, "\n ...and %zu more open end(s)", open.size() - shown);
msg += buf;
}
}
return msg;
}
TopoDS_Wire CadDocument::build_sketch_wire(const CadFeature& sketch, bool closed_only) const
{
if (!sketch.entities.empty()) {
TopoDS_Wire w = SketchEngine::entities_to_wire(sketch.entities, sketch.plane);
TopoDS_Wire w = SketchEngine::entities_to_wire(sketch.entities, sketch.plane, closed_only);
if (!w.IsNull()) return w;
// An entity sketch that yields no wire is an ERROR, not a cue to fall through. The
// legacy tail of this function ends in a default rectangle built from width/height,
@@ -2123,9 +2147,10 @@ TopoDS_Wire CadDocument::build_sketch_wire(const CadFeature& sketch) const
// looked deliberate. The legacy profile/shape paths below are still reached by sketches
// that legitimately carry no entities at all.
throw std::runtime_error(
"sketch has entities but they do not form a single closed wire — a closed entity "
"(circle/ellipse) combined with other entities, or several closed entities, is not "
"supported yet");
open_loop_message(sketch,
"sketch has entities but they do not form a single closed wire — a closed "
"entity (circle/ellipse) combined with other entities, or several closed "
"entities, is not supported yet"));
}
if (!sketch.profile.points.empty()) {
SketchProfile prof = sketch.profile;
@@ -2157,12 +2182,15 @@ TopoDS_Wire CadDocument::build_sketch_wire(const CadFeature& sketch) const
TopoDS_Face CadDocument::build_sketch_face(const CadFeature& sketch) const
{
if (!sketch.entities.empty()) {
const std::vector<TopoDS_Wire> loops = SketchEngine::entities_to_wires(sketch.entities, sketch.plane);
const std::vector<TopoDS_Wire> loops = SketchEngine::entities_to_wires(sketch.entities, sketch.plane, true);
if (loops.empty())
throw std::runtime_error("sketch entities do not form a closed loop");
// Same courtesy as build_sketch_wire: name WHERE the sketch is open. Extrude
// reaches its failure through here, not through build_sketch_wire, so without
// this the most common way to hit an open profile is also the least informative.
throw std::runtime_error(open_loop_message(sketch));
return SketchEngine::wires_to_face(loops, sketch.plane);
}
return BRepBuilderAPI_MakeFace(build_sketch_wire(sketch)).Face();
return BRepBuilderAPI_MakeFace(build_sketch_wire(sketch, true)).Face();
}
void CadDocument::apply_feature(TopoDS_Shape& result, bool& have_body,
@@ -2232,7 +2260,7 @@ void CadDocument::apply_feature(TopoDS_Shape& result, bool& have_body,
for (TopExp_Explorer ex(profile, TopAbs_WIRE); ex.More(); ex.Next()) ++nloops;
if (nloops > 1)
throw std::runtime_error("tapered extrude of a sketch with holes is not supported yet");
return SketchEngine::make_extrude_taper(build_sketch_wire(sk), sk.plane, L, f.taper_deg);
return SketchEngine::make_extrude_taper(build_sketch_wire(sk, true), sk.plane, L, f.taper_deg);
};
TopoDS_Shape t;
switch (f.extrude_end) {
@@ -2294,7 +2322,7 @@ void CadDocument::apply_feature(TopoDS_Shape& result, bool& have_body,
&& (features[f.sketch_ref].type == CadFeatureType::Sketch
|| features[f.sketch_ref].type == CadFeatureType::Project))
? features[f.sketch_ref] : f;
TopoDS_Wire wire = build_sketch_wire(sk);
TopoDS_Wire wire = build_sketch_wire(sk, true);
const double ang = f.flip ? -f.revolve_angle : f.revolve_angle;
TopoDS_Shape tool = SketchEngine::make_revolve(wire, sk.plane, ang, f.revolve_axis);
if (!have_body || f.mode == BooleanMode::New) {
@@ -2404,7 +2432,7 @@ void CadDocument::apply_feature(TopoDS_Shape& result, bool& have_body,
} else {
throw std::runtime_error("sweep path must be a sketch or helix");
}
TopoDS_Wire profile = build_sketch_wire(sk);
TopoDS_Wire profile = build_sketch_wire(sk, true);
TopoDS_Shape tool = SketchEngine::make_sweep(profile, path);
if (!have_body || f.mode == BooleanMode::New) {
result = tool;
@@ -2433,7 +2461,7 @@ void CadDocument::apply_feature(TopoDS_Shape& result, bool& have_body,
|| (features[ref].type != CadFeatureType::Sketch
&& features[ref].type != CadFeatureType::Project))
continue;
profiles.push_back(build_sketch_wire(features[ref]));
profiles.push_back(build_sketch_wire(features[ref], true));
}
if (profiles.size() < 2)
throw std::runtime_error("loft needs 2+ valid profile sketches");
src/libslic3r/CAD/CadDocument.hpp
+1 -1
View File
@@ -722,7 +722,7 @@ public:
std::vector<TriangleMesh>& out_body_meshes, std::string& err) const;
private:
TopoDS_Wire build_sketch_wire(const CadFeature& sketch) const;
TopoDS_Wire build_sketch_wire(const CadFeature& sketch, bool closed_only = false) const;
// The planar region an Extrude sweeps: the sketch's outer loop with its inner loops as
// holes. Falls back to a face over build_sketch_wire() for the legacy profile/shape paths,
// which have no concept of a second loop.
src/libslic3r/CAD/SketchEngine.cpp
+78 -6
View File
@@ -542,7 +542,8 @@ TriangleMesh SketchEngine::tessellate(const TopoDS_Shape& shape,
}
std::vector<TopoDS_Wire> SketchEngine::entities_to_wires(const std::vector<SketchEntity>& entities,
const SketchPlane& plane)
const SketchPlane& plane,
bool closed_only)
{
// Effective weld tolerance: kSketchJoinTol when auto-close is on, 0.0 when off.
// Read ONCE so the union-find, the node weld and the vertex tolerance below all
@@ -733,9 +734,10 @@ std::vector<TopoDS_Wire> SketchEngine::entities_to_wires(const std::vector<Sketc
size_t start = 0;
for (size_t i = 0; i < ms.size(); ++i)
if (node_deg[ms[i].a] == 1 || node_deg[ms[i].b] == 1) { start = i; break; }
int open = (node_deg[ms[start].a] == 1) ? ms[start].a
: (node_deg[ms[start].b] == 1) ? ms[start].b
: ms[start].a;
const int start_node = (node_deg[ms[start].a] == 1) ? ms[start].a
: (node_deg[ms[start].b] == 1) ? ms[start].b
: ms[start].a;
int open = start_node;
for (;;) {
size_t next = ms.size();
for (size_t k = 0; k < ms.size(); ++k) {
@@ -749,6 +751,27 @@ std::vector<TopoDS_Wire> SketchEngine::entities_to_wires(const std::vector<Sketc
}
if (order.size() != ms.size()) return {};
// The walk ends on the node it could not leave; that node equals the starting
// node exactly when the chain is a closed cycle. When closed_only is set, an open
// chain is DISCARDED (skipped), never an error: the viewport discards open chains
// when it decides a region is extrudable (region_loops exists to find EXTRUDABLE
// regions), so the kernel must discard them too, or the two disagree about what
// belongs to the profile and a stray click breaks a feature that looks perfect on
// screen. Reuses the welded node ids — no second tolerance.
// A component is OPEN exactly when some welded node has only one edge on it —
// that free endpoint is where the chain stops. Do NOT define it as "the walk
// returned to its starting node": a legitimately closed loop that also carries an
// extra edge between two of its nodes (a bridge added across a C profile, so the
// gap is spanned twice) has no free endpoint but its Eulerian walk still ends
// somewhere else, and that definition discarded it. Degree-1 is the property that
// actually distinguishes a stray segment from a closed profile.
if (closed_only) {
bool has_free_end = false;
for (const Member& mm : ms)
if (node_deg[mm.a] == 1 || node_deg[mm.b] == 1) { has_free_end = true; break; }
if (has_free_end) continue;
}
// One TopoDS_Vertex per node at the welded world point. Tolerance widened to
// `tol` because MakeEdge(curve, va, vb) projects each vertex onto the
// curve within the vertex tolerance (BRepLib_MakeEdge::Init), and a welded node
@@ -811,12 +834,61 @@ std::vector<TopoDS_Wire> SketchEngine::entities_to_wires(const std::vector<Sketc
}
TopoDS_Wire SketchEngine::entities_to_wire(const std::vector<SketchEntity>& entities,
const SketchPlane& plane)
const SketchPlane& plane,
bool closed_only)
{
const std::vector<TopoDS_Wire> w = entities_to_wires(entities, plane);
const std::vector<TopoDS_Wire> w = entities_to_wires(entities, plane, closed_only);
return w.size() == 1 ? w[0] : TopoDS_Wire{};
}
std::vector<Vec2d> sketch_open_ends(const std::vector<SketchEntity>& entities,
const SketchPlane& /*plane*/)
{
const double tol = sketch_join_tol();
auto is_chain = [](const SketchEntity& e) {
return e.type == SketchEntity::Type::Line || e.type == SketchEntity::Type::Arc ||
e.type == SketchEntity::Type::EllipseArc || e.type == SketchEntity::Type::BSpline;
};
auto endpoints = [](const SketchEntity& e, Vec2d& a, Vec2d& b) -> bool {
if (e.type == SketchEntity::Type::BSpline) {
if (e.ctrl.size() < 2) return false;
a = e.ctrl.front(); b = e.ctrl.back();
return true;
}
a = e.p0; b = e.p1;
return true;
};
// Weld every chain endpoint into a shared node under the SAME tolerance the wire
// build uses, then report the degree-1 nodes: they are where a chain fails to close.
// Circle/Ellipse are always closed and contribute no endpoint.
std::vector<Vec2d> node_pt;
std::vector<int> node_deg;
auto node_id = [&](const Vec2d& p) -> int {
for (size_t i = 0; i < node_pt.size(); ++i)
if ((node_pt[i] - p).norm() <= tol) return int(i);
node_pt.push_back(p);
node_deg.push_back(0);
return int(node_pt.size()) - 1;
};
for (const SketchEntity& e : entities) {
if (e.construction) continue;
if (!is_chain(e)) continue;
Vec2d a, b;
if (!endpoints(e, a, b)) continue;
int ia = node_id(a), ib = node_id(b);
node_deg[ia]++;
node_deg[ib]++;
}
std::vector<Vec2d> out;
for (size_t i = 0; i < node_pt.size(); ++i)
if (node_deg[i] == 1) out.push_back(node_pt[i]);
return out;
}
TopoDS_Face SketchEngine::wires_to_face(const std::vector<TopoDS_Wire>& wires,
const SketchPlane& plane)
{
src/libslic3r/CAD/SketchEngine.hpp
+12 -5
View File
@@ -288,15 +288,18 @@ public:
double angular_deflection = 0.5);
static TopoDS_Wire entities_to_wire(const std::vector<SketchEntity>& entities,
const SketchPlane& plane);
const SketchPlane& plane,
bool closed_only = false);
// Every closed loop the sketch holds, in the order each loop's FIRST entity appears in
// Every loop the sketch holds, in the order each loop's FIRST entity appears in
// `entities`. A Circle or Ellipse is a loop on its own; Line/Arc/EllipseArc/BSpline
// entities are grouped into loops by shared endpoints. An OPEN chain is returned too —
// a sweep path is legitimately open, so open-ness is not an error here.
// Empty vector = nothing usable; the caller decides whether that is an error.
// a sweep path is legitimately open, so open-ness is not an error here — unless
// `closed_only` is true, in which case an open chain is DISCARDED (skipped, not an
// error). Empty vector = nothing usable; the caller decides whether that is an error.
static std::vector<TopoDS_Wire> entities_to_wires(const std::vector<SketchEntity>& entities,
const SketchPlane& plane);
const SketchPlane& plane,
bool closed_only = false);
// A planar face from a set of coplanar loops: the largest-area loop is the outer boundary
// and every other loop is a hole in it. Throws std::runtime_error with a message naming the
@@ -361,6 +364,10 @@ public:
const SketchEntity& b, int b_end);
};
// Free endpoints of a sketch: the sketch-space points where a chain fails to close.
// Same weld tolerance as the wire build, so it can never contradict it.
std::vector<Vec2d> sketch_open_ends(const std::vector<SketchEntity>&, const SketchPlane&);
} // namespace Slic3r
#endif // slic3r_SketchEngine_hpp_