Former/unwrap.go

package main

import (
	"fmt"
	"math"
	"strings"
)

type TabSlot struct {
	X float64 `json:"x"`
	Y float64 `json:"y"`
	W float64 `json:"w"`
	H float64 `json:"h"`
}

type UnwrapPanel struct {
	Label    string    `json:"label"`
	FaceType string    `json:"faceType"` // "lid", "tray", "side"
	SideNum  int       `json:"sideNum"`
	X        float64   `json:"x"`
	Y        float64   `json:"y"`
	Width    float64   `json:"width"`
	Height   float64   `json:"height"`
	Angle    float64   `json:"angle"`
	Cutouts  []Cutout  `json:"cutouts"`
	TabSlots []TabSlot `json:"tabSlots"`
	// Polygon outline for non-rectangular panels (lid/tray)
	Polygon [][2]float64 `json:"polygon,omitempty"`
}

type UnwrapLayout struct {
	Panels    []UnwrapPanel `json:"panels"`
	TotalW    float64       `json:"totalW"`
	TotalH    float64       `json:"totalH"`
	WallThick float64       `json:"wallThick"`
}

// offsetPolygon moves each vertex outward along the average of its two adjacent edge normals.
func offsetPolygon(poly [][2]float64, dist float64) [][2]float64 {
	n := len(poly)
	if n < 3 {
		return poly
	}
	// Remove closing duplicate if present
	last := poly[n-1]
	first := poly[0]
	closed := math.Abs(last[0]-first[0]) < 0.01 && math.Abs(last[1]-first[1]) < 0.01
	if closed {
		n--
	}

	// Compute centroid to determine winding
	cx, cy := 0.0, 0.0
	for i := 0; i < n; i++ {
		cx += poly[i][0]
		cy += poly[i][1]
	}
	cx /= float64(n)
	cy /= float64(n)

	// Compute signed area to detect winding direction
	area := 0.0
	for i := 0; i < n; i++ {
		j := (i + 1) % n
		area += poly[i][0]*poly[j][1] - poly[j][0]*poly[i][1]
	}
	sign := 1.0
	if area > 0 {
		sign = -1.0
	}

	out := make([][2]float64, n)
	for i := 0; i < n; i++ {
		prev := (i - 1 + n) % n
		next := (i + 1) % n

		// Edge vectors
		e1x := poly[i][0] - poly[prev][0]
		e1y := poly[i][1] - poly[prev][1]
		e2x := poly[next][0] - poly[i][0]
		e2y := poly[next][1] - poly[i][1]

		// Outward normals (perpendicular, pointing away from center)
		n1x := -e1y * sign
		n1y := e1x * sign
		n2x := -e2y * sign
		n2y := e2x * sign

		// Normalize
		l1 := math.Sqrt(n1x*n1x + n1y*n1y)
		l2 := math.Sqrt(n2x*n2x + n2y*n2y)
		if l1 > 0 {
			n1x /= l1
			n1y /= l1
		}
		if l2 > 0 {
			n2x /= l2
			n2y /= l2
		}

		// Average normal
		ax := (n1x + n2x) / 2
		ay := (n1y + n2y) / 2
		al := math.Sqrt(ax*ax + ay*ay)
		if al < 1e-9 {
			out[i] = poly[i]
			continue
		}
		ax /= al
		ay /= al

		// Half-angle cosine
		dot := n1x*n2x + n1y*n2y
		halfAngle := math.Acos(math.Max(-1, math.Min(1, dot))) / 2
		cosHalf := math.Cos(halfAngle)
		if cosHalf < 0.1 {
			cosHalf = 0.1
		}

		scale := dist / cosHalf
		out[i] = [2]float64{poly[i][0] + ax*scale, poly[i][1] + ay*scale}
	}

	// Close the polygon
	out = append(out, out[0])
	return out
}

// ComputeUnwrapLayout generates a flat unfolded net of the enclosure's outer surface.
func ComputeUnwrapLayout(session *EnclosureSession, cutouts []Cutout) *UnwrapLayout {
	cfg := session.Config
	wt := cfg.WallThickness
	clearance := cfg.Clearance
	offset := clearance + 2*wt

	outlinePoly := ExtractPolygonFromGerber(session.OutlineGf)
	if len(outlinePoly) < 3 {
		return nil
	}

	lidPoly := offsetPolygon(outlinePoly, offset)

	// Bounding box of the lid polygon
	lidMinX, lidMinY := math.Inf(1), math.Inf(1)
	lidMaxX, lidMaxY := math.Inf(-1), math.Inf(-1)
	for _, p := range lidPoly {
		if p[0] < lidMinX { lidMinX = p[0] }
		if p[1] < lidMinY { lidMinY = p[1] }
		if p[0] > lidMaxX { lidMaxX = p[0] }
		if p[1] > lidMaxY { lidMaxY = p[1] }
	}
	lidW := lidMaxX - lidMinX
	lidH := lidMaxY - lidMinY

	wallH := cfg.WallHeight + cfg.PCBThickness + 1.0

	sides := session.Sides
	if len(sides) == 0 {
		return nil
	}

	// Normalize lid polygon to origin for the SVG layout
	normLidPoly := make([][2]float64, len(lidPoly))
	for i, p := range lidPoly {
		normLidPoly[i] = [2]float64{p[0] - lidMinX, p[1] - lidMinY}
	}

	// Classify cutouts by surface
	sideCutouts, lidCutouts := SplitCutouts(cutouts, nil)
	_ = lidCutouts

	// Pry tab positions
	pryW := 8.0
	pryH := 1.5

	// Find longest side for tray attachment
	longestIdx := 0
	longestLen := 0.0
	for i, s := range sides {
		if s.Length > longestLen {
			longestLen = s.Length
			longestIdx = i
		}
	}

	// Layout: lid at center, sides folded out from lid edges
	// We place lid at a starting position, then attach side panels along each edge.
	// Simple cross layout: lid centered, sides extending outward.

	margin := 5.0
	layoutX := margin
	layoutY := margin

	var panels []UnwrapPanel

	// Lid panel
	lidPanel := UnwrapPanel{
		Label:    "L",
		FaceType: "lid",
		X:        layoutX,
		Y:        layoutY + wallH, // sides above will fold up
		Width:    lidW,
		Height:   lidH,
		Polygon:  normLidPoly,
	}

	// Map lid cutouts
	for _, c := range cutouts {
		if c.Surface == "top" {
			mapped := c
			mapped.X = c.X - lidMinX + lidPanel.X
			mapped.Y = c.Y - lidMinY + lidPanel.Y
			lidPanel.Cutouts = append(lidPanel.Cutouts, mapped)
		}
	}
	panels = append(panels, lidPanel)

	// Side panels: attach along each edge of the lid
	// For simplicity, we place sides in a strip below the lid, left to right
	sideX := margin
	sideY := lidPanel.Y + lidH // below the lid

	for i, s := range sides {
		sp := UnwrapPanel{
			Label:    fmt.Sprintf("S%d", s.Num),
			FaceType: "side",
			SideNum:  s.Num,
			X:        sideX,
			Y:        sideY,
			Width:    s.Length,
			Height:   wallH,
			Angle:    s.Angle,
		}

		// Map side cutouts to this panel
		for _, sc := range sideCutouts {
			if sc.Side == s.Num {
				mapped := Cutout{
					ID:      fmt.Sprintf("unwrap-s%d", sc.Side),
					Surface: "side",
					SideNum: sc.Side,
					X:       sc.X + sp.X,
					Y:       sc.Y + sp.Y,
					Width:   sc.Width,
					Height:  sc.Height,
				}
				sp.Cutouts = append(sp.Cutouts, mapped)
			}
		}

		// Tab slots on pry tab sides
		if s.Num == 1 || s.Num == len(sides) {
			slot := TabSlot{
				X: sp.Width/2 - pryW/2,
				Y: 0,
				W: pryW,
				H: pryH,
			}
			sp.TabSlots = append(sp.TabSlots, slot)
		}

		panels = append(panels, sp)

		// If this is the longest side, attach tray below it
		if i == longestIdx {
			trayPanel := UnwrapPanel{
				Label:    "T",
				FaceType: "tray",
				X:        sideX,
				Y:        sideY + wallH,
				Width:    lidW,
				Height:   lidH,
				Polygon:  normLidPoly,
			}
			for _, c := range cutouts {
				if c.Surface == "bottom" {
					mapped := c
					mapped.X = c.X - lidMinX + trayPanel.X
					mapped.Y = c.Y - lidMinY + trayPanel.Y
					trayPanel.Cutouts = append(trayPanel.Cutouts, mapped)
				}
			}
			panels = append(panels, trayPanel)
		}

		sideX += s.Length + 2.0
	}

	// Compute total layout bounds
	totalW := margin
	totalH := margin
	for _, p := range panels {
		right := p.X + p.Width
		bottom := p.Y + p.Height
		if right > totalW { totalW = right }
		if bottom > totalH { totalH = bottom }
	}
	totalW += margin
	totalH += margin

	return &UnwrapLayout{
		Panels:    panels,
		TotalW:    totalW,
		TotalH:    totalH,
		WallThick: wt,
	}
}

// GenerateUnwrapSVG produces an SVG string of the unfolded enclosure net.
func GenerateUnwrapSVG(layout *UnwrapLayout) string {
	if layout == nil {
		return ""
	}

	var b strings.Builder
	b.WriteString(fmt.Sprintf(`<svg xmlns="http://www.w3.org/2000/svg" viewBox="0 0 %.2f %.2f" width="%.2fmm" height="%.2fmm">`+"\n",
		layout.TotalW, layout.TotalH, layout.TotalW, layout.TotalH))

	b.WriteString(`<style>`)
	b.WriteString(`.panel { fill: none; stroke: #333; stroke-width: 0.3; }`)
	b.WriteString(`.cutout { fill: #e0e0e0; stroke: #999; stroke-width: 0.2; }`)
	b.WriteString(`.tab-slot { fill: #ccc; stroke: #999; stroke-width: 0.15; }`)
	b.WriteString(`.fold-line { stroke: #aaa; stroke-width: 0.15; stroke-dasharray: 2,1; }`)
	b.WriteString(`.label { font-family: sans-serif; font-size: 4px; fill: #666; text-anchor: middle; dominant-baseline: central; }`)
	b.WriteString("</style>\n")

	for _, p := range layout.Panels {
		b.WriteString(fmt.Sprintf(`<g id="panel-%s" data-face="%s" data-side="%d" data-x="%.2f" data-y="%.2f" data-w="%.2f" data-h="%.2f">`+"\n",
			p.Label, p.FaceType, p.SideNum, p.X, p.Y, p.Width, p.Height))

		// Panel outline
		if len(p.Polygon) > 2 {
			b.WriteString(`<path class="panel" d="`)
			for i, pt := range p.Polygon {
				cmd := "L"
				if i == 0 {
					cmd = "M"
				}
				b.WriteString(fmt.Sprintf("%s%.3f,%.3f ", cmd, pt[0]+p.X, pt[1]+p.Y))
			}
			b.WriteString("Z\" />\n")
		} else {
			b.WriteString(fmt.Sprintf(`<rect class="panel" x="%.3f" y="%.3f" width="%.3f" height="%.3f" />`+"\n",
				p.X, p.Y, p.Width, p.Height))
		}

		// Cutouts
		for _, c := range p.Cutouts {
			if c.Shape == "circle" {
				r := c.Width / 2
				b.WriteString(fmt.Sprintf(`<circle class="cutout" cx="%.3f" cy="%.3f" r="%.3f" />`+"\n",
					c.X+r, c.Y+r, r))
			} else {
				b.WriteString(fmt.Sprintf(`<rect class="cutout" x="%.3f" y="%.3f" width="%.3f" height="%.3f" />`+"\n",
					c.X, c.Y, c.Width, c.Height))
			}
		}

		// Tab slots
		for _, t := range p.TabSlots {
			b.WriteString(fmt.Sprintf(`<rect class="tab-slot" x="%.3f" y="%.3f" width="%.3f" height="%.3f" />`+"\n",
				p.X+t.X, p.Y+t.Y, t.W, t.H))
		}

		// Label
		cx := p.X + p.Width/2
		cy := p.Y + p.Height/2
		b.WriteString(fmt.Sprintf(`<text class="label" x="%.2f" y="%.2f">%s</text>`+"\n", cx, cy, p.Label))

		b.WriteString("</g>\n")
	}

	// Fold lines between lid and side panels
	for _, p := range layout.Panels {
		if p.FaceType == "side" {
			b.WriteString(fmt.Sprintf(`<line class="fold-line" x1="%.3f" y1="%.3f" x2="%.3f" y2="%.3f" />`+"\n",
				p.X, p.Y, p.X+p.Width, p.Y))
		}
		if p.FaceType == "tray" {
			b.WriteString(fmt.Sprintf(`<line class="fold-line" x1="%.3f" y1="%.3f" x2="%.3f" y2="%.3f" />`+"\n",
				p.X, p.Y, p.X+p.Width, p.Y))
		}
	}

	b.WriteString("</svg>")
	return b.String()
}