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Add filleted rectangle cutouts#54

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jasonmadigan merged 4 commits into
tracefinity:mainfrom
noobydp:codex/cylinder-cutouts-tools
Jun 14, 2026
Merged

Add filleted rectangle cutouts#54
jasonmadigan merged 4 commits into
tracefinity:mainfrom
noobydp:codex/cylinder-cutouts-tools

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@noobydp

@noobydp noobydp commented May 31, 2026 •
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Summary

  • Add filleted_rectangle as a supported cutout shape across backend schema, frontend types, and the tool editor cutout menu.
  • Generate a full-depth rounded-bottom rectangle cutter in STL output, with fillet radius clamped to min(width / 3, cutout_depth / 2).
  • Treat filleted rectangles like rectangles for placement, resizing, rotation, selection labels, and bin/editor visualization.
  • Render filleted rectangle overlays as a single matching-outline shape instead of a separate blue indicator line.
  • Document the STL generation behavior and add focused backend coverage for radius clamping, full-depth reach, and chamfer cutter creation.

Testing

  • python -m py_compile backend\app\services\stl_generator_manifold.py backend\tests\test_cylinder_shape.py
  • PYTHONPATH="$env:TEMP\codex-manifold3d-inspect;D:\Development\tracefinity-cylinder-cutouts\backend" python -m pytest backend\tests\test_cylinder_shape.py -q
  • npx tsc --noEmit
  • npm run build
  • Browser smoke reload at http://localhost:4002/ with no build-error overlay or console errors.

Disclaimer

Code and PR drafted with Codex

@noobydp noobydp marked this pull request as ready for review May 31, 2026 16:03
@noobydp

noobydp commented Jun 3, 2026

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Update after conflict-reduction pass:

  • Added Move cutout type declaration (0e8c93d).
  • Moved the CutoutShape type declaration in frontend/src/types/index.ts away from the top-of-file area used by the photo-station PR.
  • No behavior changes: FingerHole.shape?: CutoutShape and all filleted rectangle behavior remain unchanged.

Validation for this follow-up:

  • frontend\node_modules\.bin\tsc.cmd -p frontend\tsconfig.json --noEmit

Pairwise merge status after this update:

@noobydp noobydp mentioned this pull request Jun 3, 2026
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jasonmadigan
jasonmadigan requested changes Jun 3, 2026
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changes requested

blockers

SVG/STL fillet radius mismatch -- CutoutOverlay.tsx computes filletR = Math.min(w/3, h/2) where h is rectangle height. Backend _filleted_rect_radius computes min(width/3, pocket_depth/2) where the second term is pocket depth (Z-axis). The preview won't match the printed shape whenever pocket_depth != height.

profile winding direction unverified -- _rounded_bottom_rect_profile_pts docstring says "CCW x/z profile" but the point order appears clockwise. manifold3d CrossSection requires CCW. Tests pass (manifold3d may auto-correct), but should use _ensure_ccw() like elsewhere in the file rather than relying on implicit behaviour.

should fix

z_margin bleed in Y -- _make_filleted_rectangle_cutter applies z_margin to the Y-dimension length (length = h + z_margin * 2). The cutter overshoots 0.005mm per side in Y. Fix: length = h.

test coverage gaps -- zero fillet radius, fillet = half width, negative dimensions, rotation, and the profile point positions are all untested.

nits

  • cutoutShapeLabel switch could be a Record<CutoutShape, string> for exhaustiveness checking
  • duplicated ternary chains for isCutoutMode/cutoutModeIcon/cutoutModeLabel in ToolEditor (existing tech debt made slightly worse)

overall solid contribution -- the schema change is backward compatible, the CutoutShape type extraction is clean, and the chamfer grouping is correct. The preview mismatch is the main concern.

@noobydp

noobydp commented Jun 9, 2026

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Updated PR #54 to address the requested changes.

Changes made:

  • Aligned the SVG preview fillet radius with STL generation by clamping against cutout depth instead of rectangle height.
  • In bin preview, resolved cutout depth the same way as backend generation: hole override, then tool override, then bin default.
  • Explicitly normalized the rounded-bottom profile to CCW before passing it to CrossSection.
  • Removed the small Y-axis length overshoot from the filleted rectangle cutter.
  • Expanded backend coverage for zero fillets, half-width fillets, negative dimensions, profile key points, rotation, exact Y extent, and winding.
  • Switched cutoutShapeLabel to an exhaustive Record<CutoutShape, string>.

Validation:

  • py_compile passed
  • backend/tests/test_cylinder_shape.py -q: 13 passed
  • npx tsc --noEmit passed
  • npm run build passed
  • git diff --check clean except local CRLF notices

That covers the blockers, should-fix items, and the cutoutShapeLabel nit. I left the duplicated ToolEditor ternary chain alone because it is existing UI tech debt and refactoring it is not needed for this correctness fix.

@noobydp
Merge remote-tracking branch 'upstream/main' into codex/cylinder-cuto…
10f0ec1 
…uts-tools

# Conflicts:
#	frontend/src/components/BinEditorToolbar.tsx
@jasonmadigan

jasonmadigan commented Jun 14, 2026

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thanks @noobydp!

@jasonmadigan jasonmadigan merged commit d9cd90f into tracefinity:main Jun 14, 2026
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