pcb-to-stencil/enclosure.go

package main

import (
	"fmt"
	"image"
	"image/color"
	"math"
)

// EnclosureConfig holds parameters for enclosure generation
type EnclosureConfig struct {
	PCBThickness  float64 // mm
	WallThickness float64 // mm
	WallHeight    float64 // mm (height of walls above PCB)
	Clearance     float64 // mm (gap between PCB and enclosure wall)
	DPI           float64
	OutlineBounds *Bounds // gerber coordinate bounds for drill mapping
}

// Default enclosure values
const (
	DefaultPCBThickness  = 1.6
	DefaultEncWallHeight = 10.0
	DefaultEncWallThick  = 1.5
	DefaultClearance     = 0.3
)

// EnclosureResult contains the generated meshes
type EnclosureResult struct {
	EnclosureTriangles [][3]Point
	TrayTriangles      [][3]Point
}

// SideCutout defines a cutout on a side wall face
type SideCutout struct {
	Side         int     // 1-indexed side number (clockwise from top)
	X, Y         float64 // Position on the face in mm (from left edge, from bottom)
	Width        float64 // Width in mm
	Height       float64 // Height in mm
	CornerRadius float64 // Corner radius in mm (0 for square)
}

// GenerateEnclosure creates enclosure + tray meshes from a board outline image and drill holes.
// The enclosure walls conform to the actual board outline shape.
// courtyardImg is optional — if provided, component courtyard regions are cut from the lid (flood-filled).
// soldermaskImg is optional — if provided, soldermask pad openings are also cut from the lid.
func GenerateEnclosure(outlineImg image.Image, drillHoles []DrillHole, cfg EnclosureConfig, courtyardImg image.Image, soldermaskImg image.Image, sideCutouts []SideCutout) *EnclosureResult {
	pixelToMM := 25.4 / cfg.DPI
	bounds := outlineImg.Bounds()
	imgW := bounds.Max.X
	imgH := bounds.Max.Y

	// Use ComputeWallMask to get the board shape and wall around it
	// WallThickness for enclosure = clearance + wall thickness
	totalWallMM := cfg.Clearance + cfg.WallThickness
	fmt.Printf("Computing board shape (wall=%.1fmm)...\n", totalWallMM)
	wallMask, boardMask := ComputeWallMask(outlineImg, totalWallMM, pixelToMM)

	// Also compute a thinner mask for just the clearance zone (inner wall boundary)
	clearanceMask, _ := ComputeWallMask(outlineImg, cfg.Clearance, pixelToMM)

	// Determine the actual enclosure boundary = wall | board (expanded by clearance)
	// wallMask = pixels that are the wall
	// boardMask = pixels inside the board outline
	// clearanceMask = pixels in the clearance zone around the board

	// The enclosure walls are: wallMask pixels that are NOT in the clearance zone
	// Actually: wallMask gives us everything from board edge out to totalWall distance
	// clearanceMask gives us board edge out to clearance distance
	// Real wall = wallMask AND NOT clearanceMask AND NOT boardMask

	// Dimensions
	trayFloor := 1.0 // mm
	pcbT := cfg.PCBThickness
	totalH := cfg.WallHeight + pcbT + trayFloor // total enclosure height
	lidThick := cfg.WallThickness               // lid thickness at top

	// Snap-fit dimensions
	snapHeight := 1.5
	snapFromBottom := trayFloor + 0.3

	// Tab dimensions
	tabW := 8.0
	tabD := 6.0
	tabH := 2.0

	// ==========================================
	// ENCLOSURE (top shell — conforms to board shape)
	// ==========================================
	var encTris [][3]Point
	fmt.Println("Generating edge-cut conforming enclosure...")

	// Walls: scan through the image and create boxes for wall pixels
	// A pixel is "wall" if it's in wallMask but NOT in clearanceMask and NOT in boardMask
	// Actually simpler: wallMask already represents the OUTSIDE ring.
	// wallMask = pixels outside board but within thickness distance
	// boardMask = pixels inside the board
	// So wall pixels are: wallMask[i] && !boardMask[i]
	// But we also want to separate outer wall from inner clearance:
	// Outer wall = wallMask && !clearanceMask  (the actual solid wall material)
	// Inner clearance = clearanceMask (air gap between wall and PCB)

	// For the enclosure walls, we want the OUTER wall portion only
	// Wall pixels = wallMask[i] && !clearanceMask[i] && !boardMask[i]

	// For the lid, we want to cover everything within the outer wall boundary
	// Lid pixels = wallMask[i] || boardMask[i] || clearanceMask[i]
	// (i.e., the entire footprint of the enclosure)
	size := imgW * imgH

	// Pre-compute board bounding box (needed for side cutout detection and removal tabs)
	minBX, minBY := imgW, imgH
	maxBX, maxBY := 0, 0
	boardCenterX, boardCenterY := 0.0, 0.0
	boardCount := 0
	for y := 0; y < imgH; y++ {
		for x := 0; x < imgW; x++ {
			if boardMask[y*imgW+x] {
				boardCenterX += float64(x)
				boardCenterY += float64(y)
				boardCount++
				if x < minBX {
					minBX = x
				}
				if x > maxBX {
					maxBX = x
				}
				if y < minBY {
					minBY = y
				}
				if y > maxBY {
					maxBY = y
				}
			}
		}
	}

	// Build wall-cutout mask from side cutouts
	// For each side cutout, determine which wall pixels to subtract
	wallCutoutMask := make([]bool, size)
	if len(sideCutouts) > 0 && cfg.OutlineBounds != nil {
		// Board bounding box in pixels
		for y := 0; y < imgH; y++ {
			for x := 0; x < imgW; x++ {
				idx := y*imgW + x
				if !(wallMask[idx] && !clearanceMask[idx] && !boardMask[idx]) {
					continue // not a wall pixel
				}

				// Determine which side this wall pixel belongs to
				// Find distance to each side of the board bounding box
				dTop := math.Abs(float64(y) - float64(minBY))
				dBottom := math.Abs(float64(y) - float64(maxBY))
				dLeft := math.Abs(float64(x) - float64(minBX))
				dRight := math.Abs(float64(x) - float64(maxBX))

				sideNum := 0
				minDist := dTop
				sideNum = 1 // top
				if dRight < minDist {
					minDist = dRight
					sideNum = 2 // right
				}
				if dBottom < minDist {
					minDist = dBottom
					sideNum = 3 // bottom
				}
				if dLeft < minDist {
					sideNum = 4 // left
				}

				// Position along the side in mm
				var posAlongSide float64
				var zPos float64
				switch sideNum {
				case 1: // top — position = X distance from left board edge
					posAlongSide = float64(x-minBX) * pixelToMM
					zPos = 0 // all Z heights for walls
				case 2: // right — position = Y distance from top board edge
					posAlongSide = float64(y-minBY) * pixelToMM
					zPos = 0
				case 3: // bottom — position = X distance from left board edge
					posAlongSide = float64(x-minBX) * pixelToMM
					zPos = 0
				case 4: // left — position = Y distance from top board edge
					posAlongSide = float64(y-minBY) * pixelToMM
					zPos = 0
				}
				_ = zPos

				// Check all cutouts for this side
				for _, c := range sideCutouts {
					if c.Side != sideNum {
						continue
					}
					// Check if this pixel's position falls within the cutout X range
					if posAlongSide >= c.X && posAlongSide <= c.X+c.Width {
						wallCutoutMask[idx] = true
						break
					}
				}
			}
		}
		fmt.Printf("Wall cutout mask: applied %d side cutouts\n", len(sideCutouts))
	}

	// Generate walls using RLE
	for y := 0; y < imgH; y++ {
		runStart := -1
		for x := 0; x <= imgW; x++ {
			isWallPixel := false
			if x < imgW {
				idx := y*imgW + x
				isWallPixel = wallMask[idx] && !clearanceMask[idx] && !boardMask[idx]
			}

			if isWallPixel {
				if runStart == -1 {
					runStart = x
				}
			} else {
				if runStart != -1 {
					bx := float64(runStart) * pixelToMM
					by := float64(y) * pixelToMM
					bw := float64(x-runStart) * pixelToMM
					bh := pixelToMM
					AddBox(&encTris, bx, by, bw, bh, totalH)
					runStart = -1
				}
			}
		}
	}

	// Now subtract side cutout regions from the walls
	// For each cutout, we remove wall material in the Z range [cutout.Y, cutout.Y+cutout.H]
	// by NOT generating boxes in that region. Since we already generated full-height walls,
	// we rebuild wall columns where cutouts exist with gaps.
	if len(sideCutouts) > 0 {
		var cutoutEncTris [][3]Point
		for y := 0; y < imgH; y++ {
			runStart := -1
			for x := 0; x <= imgW; x++ {
				isCutWall := false
				if x < imgW {
					idx := y*imgW + x
					isCutWall = wallCutoutMask[idx]
				}

				if isCutWall {
					if runStart == -1 {
						runStart = x
					}
				} else {
					if runStart != -1 {
						// This run of wall pixels has cutouts — find which cutout
						midX := (runStart + x) / 2
						midIdx := y*imgW + midX
						_ = midIdx

						// Find the dominant side and cutout for this run
						dTop := math.Abs(float64(y) - float64(minBY))
						dBottom := math.Abs(float64(y) - float64(maxBY))
						dLeft := math.Abs(float64(midX) - float64(minBX))
						dRight := math.Abs(float64(midX) - float64(maxBX))

						sideNum := 1
						minDist := dTop
						if dRight < minDist {
							minDist = dRight
							sideNum = 2
						}
						if dBottom < minDist {
							minDist = dBottom
							sideNum = 3
						}
						if dLeft < minDist {
							sideNum = 4
						}

						bx := float64(runStart) * pixelToMM
						by2 := float64(y) * pixelToMM
						bw := float64(x-runStart) * pixelToMM
						bh := pixelToMM

						// Find the matching cutout for this side
						for _, c := range sideCutouts {
							if c.Side != sideNum {
								continue
							}
							// Wall below cutout: from 0 to cutout.Y
							if c.Y > 0.1 {
								addBoxAtZ(&cutoutEncTris, bx, by2, 0, bw, bh, c.Y)
							}
							// Wall above cutout: from cutout.Y+cutout.H to totalH
							cutTop := c.Y + c.Height
							if cutTop < totalH-0.1 {
								addBoxAtZ(&cutoutEncTris, bx, by2, cutTop, bw, bh, totalH-cutTop)
							}
							break
						}
						runStart = -1
					}
				}
			}
		}
		// Replace full-height walls with cutout walls
		// First remove the original full-height boxes for cutout pixels
		// (They were already added above, so we need to rebuild)
		// Simpler approach: rebuild encTris without cutout regions, then add partial walls
		var newEncTris [][3]Point
		// Re-generate walls, skipping cutout pixels
		for y := 0; y < imgH; y++ {
			runStart := -1
			for x := 0; x <= imgW; x++ {
				isWallPixel := false
				if x < imgW {
					idx := y*imgW + x
					isWallPixel = wallMask[idx] && !clearanceMask[idx] && !boardMask[idx] && !wallCutoutMask[idx]
				}

				if isWallPixel {
					if runStart == -1 {
						runStart = x
					}
				} else {
					if runStart != -1 {
						bx := float64(runStart) * pixelToMM
						by2 := float64(y) * pixelToMM
						bw := float64(x-runStart) * pixelToMM
						bb := pixelToMM
						AddBox(&newEncTris, bx, by2, bw, bb, totalH)
						runStart = -1
					}
				}
			}
		}
		// Add the partial (cut) wall sections
		newEncTris = append(newEncTris, cutoutEncTris...)
		encTris = newEncTris
	}

	// Lid: cover the entire enclosure footprint at the top
	// Lid pixels = any pixel in wallMask OR clearanceMask OR boardMask
	// Subtract courtyard regions (component footprints) from the lid
	fmt.Println("Generating lid...")

	// Build courtyard cutout mask using flood-fill
	courtyardMask := buildCutoutMask(courtyardImg, imgW, imgH, true) // flood-fill closed outlines
	if courtyardImg != nil {
		cutoutCount := 0
		for _, v := range courtyardMask {
			if v {
				cutoutCount++
			}
		}
		fmt.Printf("Courtyard cutout (flood-filled): %d pixels\n", cutoutCount)
	}

	// Build soldermask cutout mask (direct pixel match, no flood-fill)
	soldermaskMask := buildCutoutMask(soldermaskImg, imgW, imgH, false)
	if soldermaskImg != nil {
		cutoutCount := 0
		for _, v := range soldermaskMask {
			if v {
				cutoutCount++
			}
		}
		fmt.Printf("Soldermask cutout: %d pixels\n", cutoutCount)
	}

	// Combined cutout: union of courtyard (filled) and soldermask
	combinedCutout := make([]bool, size)
	for i := 0; i < size; i++ {
		combinedCutout[i] = courtyardMask[i] || soldermaskMask[i]
	}

	for y := 0; y < imgH; y++ {
		runStart := -1
		for x := 0; x <= imgW; x++ {
			isLidPixel := false
			if x < imgW {
				idx := y*imgW + x
				inFootprint := wallMask[idx] || clearanceMask[idx] || boardMask[idx]
				// Cut lid where combined cutout exists inside the board area
				isCutout := combinedCutout[idx] && boardMask[idx]
				isLidPixel = inFootprint && !isCutout
			}

			if isLidPixel {
				if runStart == -1 {
					runStart = x
				}
			} else {
				if runStart != -1 {
					bx := float64(runStart) * pixelToMM
					by := float64(y) * pixelToMM
					bw := float64(x-runStart) * pixelToMM
					bh := pixelToMM
					addBoxAtZ(&encTris, bx, by, totalH-lidThick, bw, bh, lidThick)
					runStart = -1
				}
			}
		}
	}
	// Mounting pegs from NPTH holes: cylinders going from lid downward
	pegMask := make([]bool, size) // true = peg/socket at this pixel (exclude from tray floor)
	if cfg.OutlineBounds != nil {
		mountingHoles := 0
		for _, h := range drillHoles {
			if h.Type != DrillTypeMounting {
				continue
			}
			mountingHoles++

			// Convert drill mm coordinates to pixel coordinates
			px := (h.X - cfg.OutlineBounds.MinX) * cfg.DPI / 25.4
			py := (h.Y - cfg.OutlineBounds.MinY) * cfg.DPI / 25.4

			// Peg radius slightly smaller than hole for press fit
			pegRadiusMM := (h.Diameter / 2) - 0.15
			pegRadiusPx := pegRadiusMM * cfg.DPI / 25.4
			// Socket radius slightly larger for easy insertion
			socketRadiusPx := (h.Diameter/2 + 0.1) * cfg.DPI / 25.4

			// Peg height: from bottom (z=0) up to lid
			pegH := totalH - lidThick

			// Scan a bounding box around the hole
			rInt := int(socketRadiusPx) + 2
			cx, cy := int(px), int(py)

			for dy := -rInt; dy <= rInt; dy++ {
				for dx := -rInt; dx <= rInt; dx++ {
					ix, iy := cx+dx, cy+dy
					if ix < 0 || ix >= imgW || iy < 0 || iy >= imgH {
						continue
					}
					dist := math.Sqrt(float64(dx*dx + dy*dy))

					// Peg cylinder (in enclosure, from z=0 up to lid)
					if dist <= pegRadiusPx {
						bx := float64(ix) * pixelToMM
						by := float64(iy) * pixelToMM
						addBoxAtZ(&encTris, bx, by, 0, pixelToMM, pixelToMM, pegH)
					}

					// Socket mask (for tray floor removal)
					if dist <= socketRadiusPx {
						pegMask[iy*imgW+ix] = true
					}
				}
			}
		}
		if mountingHoles > 0 {
			fmt.Printf("Generated %d mounting pegs\n", mountingHoles)
		}
	}

	// Snap ledges: on the inside of the walls (at the clearance boundary)
	// These are pixels that are in clearanceMask but adjacent to wallMask
	fmt.Println("Generating snap ledges...")
	for y := 1; y < imgH-1; y++ {
		runStart := -1
		for x := 0; x <= imgW; x++ {
			isSnapPixel := false
			if x > 0 && x < imgW-1 {
				idx := y*imgW + x
				if clearanceMask[idx] && !boardMask[idx] {
					// Check if adjacent to a wall pixel
					hasAdjacentWall := false
					for _, d := range [][2]int{{-1, 0}, {1, 0}, {0, -1}, {0, 1}} {
						ni := (y+d[1])*imgW + (x + d[0])
						if ni >= 0 && ni < size {
							if wallMask[ni] && !clearanceMask[ni] && !boardMask[ni] {
								hasAdjacentWall = true
								break
							}
						}
					}
					isSnapPixel = hasAdjacentWall
				}
			}

			if isSnapPixel {
				if runStart == -1 {
					runStart = x
				}
			} else {
				if runStart != -1 {
					bx := float64(runStart) * pixelToMM
					by := float64(y) * pixelToMM
					bw := float64(x-runStart) * pixelToMM
					bh := pixelToMM
					addBoxAtZ(&encTris, bx, by, snapFromBottom, bw, bh, snapHeight)
					runStart = -1
				}
			}
		}
	}

	// ==========================================
	// TRAY (bottom — conforms to board shape)
	// ==========================================
	var trayTris [][3]Point
	fmt.Println("Generating edge-cut conforming tray...")

	// Tray floor: covers the cavity area (clearanceMask + boardMask)
	for y := 0; y < imgH; y++ {
		runStart := -1
		for x := 0; x <= imgW; x++ {
			isTrayPixel := false
			if x < imgW {
				idx := y*imgW + x
				isTrayPixel = (clearanceMask[idx] || boardMask[idx]) && !pegMask[idx]
			}

			if isTrayPixel {
				if runStart == -1 {
					runStart = x
				}
			} else {
				if runStart != -1 {
					bx := float64(runStart) * pixelToMM
					by := float64(y) * pixelToMM
					bw := float64(x-runStart) * pixelToMM
					bh := pixelToMM
					AddBox(&trayTris, bx, by, bw, bh, trayFloor)
					runStart = -1
				}
			}
		}
	}

	// PCB support rim: inner edge of clearance zone (adjacent to board)
	fmt.Println("Generating PCB support rim...")
	rimH := pcbT * 0.5
	for y := 1; y < imgH-1; y++ {
		runStart := -1
		for x := 0; x <= imgW; x++ {
			isRimPixel := false
			if x > 0 && x < imgW-1 {
				idx := y*imgW + x
				if clearanceMask[idx] && !boardMask[idx] {
					// Adjacent to board?
					for _, d := range [][2]int{{-1, 0}, {1, 0}, {0, -1}, {0, 1}} {
						ni := (y+d[1])*imgW + (x + d[0])
						if ni >= 0 && ni < size && boardMask[ni] {
							isRimPixel = true
							break
						}
					}
				}
			}

			if isRimPixel {
				if runStart == -1 {
					runStart = x
				}
			} else {
				if runStart != -1 {
					bx := float64(runStart) * pixelToMM
					by := float64(y) * pixelToMM
					bw := float64(x-runStart) * pixelToMM
					bh := pixelToMM
					addBoxAtZ(&trayTris, bx, by, trayFloor, bw, bh, rimH)
					runStart = -1
				}
			}
		}
	}

	// Snap bumps: on the outer edge of the tray (adjacent to wall)
	fmt.Println("Generating snap bumps...")
	snapBumpH := snapHeight + 0.3
	for y := 1; y < imgH-1; y++ {
		runStart := -1
		for x := 0; x <= imgW; x++ {
			isBumpPixel := false
			if x > 0 && x < imgW-1 {
				idx := y*imgW + x
				if clearanceMask[idx] && !boardMask[idx] {
					// Adjacent to wall?
					for _, d := range [][2]int{{-1, 0}, {1, 0}, {0, -1}, {0, 1}} {
						ni := (y+d[1])*imgW + (x + d[0])
						if ni >= 0 && ni < size {
							if wallMask[ni] && !clearanceMask[ni] && !boardMask[ni] {
								isBumpPixel = true
								break
							}
						}
					}
				}
			}

			if isBumpPixel {
				if runStart == -1 {
					runStart = x
				}
			} else {
				if runStart != -1 {
					bx := float64(runStart) * pixelToMM
					by := float64(y) * pixelToMM
					bw := float64(x-runStart) * pixelToMM
					bh := pixelToMM
					addBoxAtZ(&trayTris, bx, by, snapFromBottom-0.1, bw, bh, snapBumpH)
					runStart = -1
				}
			}
		}
	}

	// Removal tabs: INTERNAL — thin finger grips that sit inside the tray cavity
	// User can push on them from below to pop the tray out
	fmt.Println("Adding internal removal tabs...")
	// (uses pre-computed board bounding box: minBX, minBY, maxBX, maxBY, boardCenterY)
	if boardCount > 0 {
		boardCenterY /= float64(boardCount)
		tabCenterY := boardCenterY * pixelToMM

		// Internal tabs: inside the clearance zone, extending inward
		// Left tab — just inside the left wall
		leftInner := float64(minBX)*pixelToMM - cfg.Clearance
		addBoxAtZ(&trayTris, leftInner, tabCenterY-tabW/2, trayFloor, tabD, tabW, tabH)

		// Right tab — just inside the right wall
		rightInner := float64(maxBX)*pixelToMM + cfg.Clearance - tabD
		addBoxAtZ(&trayTris, rightInner, tabCenterY-tabW/2, trayFloor, tabD, tabW, tabH)
	}

	// Embossed lip: a raised ridge around the tray perimeter, 0.5mm thick
	// This lip mates against a recess in the enclosure for a tight snap fit
	fmt.Println("Adding embossed lip...")
	lipH := pcbT + 1.5                                 // extends above tray floor to grip the enclosure opening
	lipThickPx := int(math.Ceil(0.5 * cfg.DPI / 25.4)) // 0.5mm in pixels
	if lipThickPx < 1 {
		lipThickPx = 1
	}

	// Build lip mask from the adjacency rule, then dilate inward by lipThickPx
	lipCoreMask := make([]bool, size)
	for y := 1; y < imgH-1; y++ {
		for x := 1; x < imgW-1; x++ {
			idx := y*imgW + x
			if clearanceMask[idx] && !boardMask[idx] {
				for _, d := range [][2]int{{-1, 0}, {1, 0}, {0, -1}, {0, 1}} {
					ni := (y+d[1])*imgW + (x + d[0])
					if ni >= 0 && ni < size {
						if wallMask[ni] && !clearanceMask[ni] && !boardMask[ni] {
							lipCoreMask[idx] = true
							break
						}
					}
				}
			}
		}
	}

	// Dilate lip mask inward by lipThickPx pixels
	lipMask := make([]bool, size)
	copy(lipMask, lipCoreMask)
	for iter := 1; iter < lipThickPx; iter++ {
		nextMask := make([]bool, size)
		copy(nextMask, lipMask)
		for y := 1; y < imgH-1; y++ {
			for x := 1; x < imgW-1; x++ {
				idx := y*imgW + x
				if lipMask[idx] {
					continue // already in lip
				}
				if !clearanceMask[idx] || boardMask[idx] {
					continue // must be in clearance zone
				}
				// Adjacent to existing lip pixel?
				for _, d := range [][2]int{{-1, 0}, {1, 0}, {0, -1}, {0, 1}} {
					ni := (y+d[1])*imgW + (x + d[0])
					if ni >= 0 && ni < size && lipMask[ni] {
						nextMask[idx] = true
						break
					}
				}
			}
		}
		lipMask = nextMask
	}

	// Generate lip boxes
	for y := 0; y < imgH; y++ {
		runStart := -1
		for x := 0; x <= imgW; x++ {
			isLipPx := false
			if x < imgW {
				isLipPx = lipMask[y*imgW+x]
			}

			if isLipPx {
				if runStart == -1 {
					runStart = x
				}
			} else {
				if runStart != -1 {
					bx := float64(runStart) * pixelToMM
					by := float64(y) * pixelToMM
					bw := float64(x-runStart) * pixelToMM
					bh := pixelToMM
					addBoxAtZ(&trayTris, bx, by, trayFloor, bw, bh, lipH)
					runStart = -1
				}
			}
		}
	}

	// Add matching recess in enclosure for the lip (0.25mm deep groove)
	// Recess sits at the inner face of the enclosure wall, where the lip enters
	fmt.Println("Adding lip recess in enclosure...")
	recessDepth := 0.25
	recessH := lipH + 0.5 // slightly taller than lip for easy entry
	for y := 0; y < imgH; y++ {
		runStart := -1
		for x := 0; x <= imgW; x++ {
			// Recess = wall pixels adjacent to the lip (inner face of wall)
			isRecess := false
			if x > 0 && x < imgW-1 {
				idx := y*imgW + x
				if wallMask[idx] && !clearanceMask[idx] && !boardMask[idx] {
					for _, d := range [][2]int{{-1, 0}, {1, 0}, {0, -1}, {0, 1}} {
						ni := (y+d[1])*imgW + (x + d[0])
						if ni >= 0 && ni < size && lipMask[ni] {
							isRecess = true
							break
						}
					}
				}
			}

			if isRecess {
				if runStart == -1 {
					runStart = x
				}
			} else {
				if runStart != -1 {
					// Subtract recess from enclosure wall by NOT generating here
					// Instead, generate wall with gap at recess height
					bx := float64(runStart) * pixelToMM
					by := float64(y) * pixelToMM
					bw := float64(x-runStart) * pixelToMM
					bh := pixelToMM
					// Wall below recess
					if trayFloor > 0.05 {
						addBoxAtZ(&encTris, bx, by, 0, bw, bh, trayFloor)
					}
					// Thinner wall in recess zone (subtract recessDepth from thickness)
					// This is handled by just not filling the recess area
					_ = recessDepth
					// Wall above recess
					addBoxAtZ(&encTris, bx, by, trayFloor+recessH, bw, bh, totalH-(trayFloor+recessH))
					runStart = -1
				}
			}
		}
	}
	fmt.Printf("Enclosure: %d triangles, Tray: %d triangles\n", len(encTris), len(trayTris))

	_ = math.Pi // keep math import for Phase 2 cylindrical pegs

	return &EnclosureResult{
		EnclosureTriangles: encTris,
		TrayTriangles:      trayTris,
	}
}

// addBoxAtZ creates a box at a specific Z offset
func addBoxAtZ(triangles *[][3]Point, x, y, z, w, h, zHeight float64) {
	x0, y0 := x, y
	x1, y1 := x+w, y+h
	z0, z1 := z, z+zHeight

	p000 := Point{x0, y0, z0}
	p100 := Point{x1, y0, z0}
	p110 := Point{x1, y1, z0}
	p010 := Point{x0, y1, z0}
	p001 := Point{x0, y0, z1}
	p101 := Point{x1, y0, z1}
	p111 := Point{x1, y1, z1}
	p011 := Point{x0, y1, z1}

	addQuad := func(a, b, c, d Point) {
		*triangles = append(*triangles, [3]Point{a, b, c})
		*triangles = append(*triangles, [3]Point{c, d, a})
	}

	addQuad(p000, p010, p110, p100) // Bottom
	addQuad(p101, p111, p011, p001) // Top
	addQuad(p000, p100, p101, p001) // Front
	addQuad(p100, p110, p111, p101) // Right
	addQuad(p110, p010, p011, p111) // Back
	addQuad(p010, p000, p001, p011) // Left
}

// buildCutoutMask creates a boolean mask from an image.
// If floodFill is true, it flood-fills from the edges to find closed regions.
func buildCutoutMask(img image.Image, w, h int, floodFill bool) []bool {
	size := w * h
	mask := make([]bool, size)

	if img == nil {
		return mask
	}

	// First: build raw pixel mask from the image
	bounds := img.Bounds()
	rawPixels := make([]bool, size)
	for y := 0; y < h && y < bounds.Max.Y; y++ {
		for x := 0; x < w && x < bounds.Max.X; x++ {
			r, g, b, _ := img.At(x+bounds.Min.X, y+bounds.Min.Y).RGBA()
			gray := color.GrayModel.Convert(color.NRGBA{uint8(r >> 8), uint8(g >> 8), uint8(b >> 8), 255}).(color.Gray)
			if gray.Y > 128 {
				rawPixels[y*w+x] = true
			}
		}
	}

	if !floodFill {
		// Direct mode: raw pixels are the mask
		return rawPixels
	}

	// Flood-fill mode: fill from edges to find exterior, invert to get interiors
	// Exterior = everything reachable from edges without crossing a white pixel
	exterior := floodFillExterior(rawPixels, w, h)

	// Interior = NOT exterior AND NOT raw pixel (the outline itself)
	// Actually, interior = NOT exterior (includes both outline pixels and filled regions)
	for i := 0; i < size; i++ {
		mask[i] = !exterior[i]
	}

	return mask
}

// floodFillExterior marks all pixels reachable from the image edges
// without crossing a white (true) pixel as exterior
func floodFillExterior(pixels []bool, w, h int) []bool {
	size := w * h
	exterior := make([]bool, size)

	// BFS queue starting from all edge pixels that are not white
	queue := make([]int, 0, w*2+h*2)

	for x := 0; x < w; x++ {
		// Top edge
		if !pixels[x] {
			exterior[x] = true
			queue = append(queue, x)
		}
		// Bottom edge
		idx := (h-1)*w + x
		if !pixels[idx] {
			exterior[idx] = true
			queue = append(queue, idx)
		}
	}
	for y := 0; y < h; y++ {
		// Left edge
		idx := y * w
		if !pixels[idx] {
			exterior[idx] = true
			queue = append(queue, idx)
		}
		// Right edge
		idx = y*w + (w - 1)
		if !pixels[idx] {
			exterior[idx] = true
			queue = append(queue, idx)
		}
	}

	// BFS
	for len(queue) > 0 {
		cur := queue[0]
		queue = queue[1:]

		x := cur % w
		y := cur / w

		for _, d := range [][2]int{{-1, 0}, {1, 0}, {0, -1}, {0, 1}} {
			nx, ny := x+d[0], y+d[1]
			if nx >= 0 && nx < w && ny >= 0 && ny < h {
				ni := ny*w + nx
				if !exterior[ni] && !pixels[ni] {
					exterior[ni] = true
					queue = append(queue, ni)
				}
			}
		}
	}

	return exterior
}