ParaWiki/cimery/crates/kernel/src/occt.rs

//! OcctKernel — geometry backend using OpenCASCADE Technology (OCCT).
//!
//! Only compiled with `--features occt` (ADR-001, ADR-002 optional feature).
//!
//! Produces proper B-rep solids:
//! - Accurate PSC-I cross-section with haunches
//! - Higher-quality tessellation (BRepMesh_IncrementalMesh)
//! - Foundation for fillets, boolean ops in later sprints

#[cfg(feature = "occt")]
mod inner {
    use glam::DVec3;
    use opencascade::{
        mesh::Mesher,
        workplane::Workplane,
    };
    use cimery_ir::{
        AbutmentIR, BearingIR, DeckSlabIR, GirderIR, PierIR,
        PscISectionParams, SectionParams,
    };
    use crate::{KernelError, Mesh};

    // ── Girder (PSC-I B-rep sweep) ──────────────────────────────────────────────

    pub fn girder_mesh(ir: &GirderIR) -> Result<Mesh, KernelError> {
        if ir.span_m() <= 0.0 {
            return Err(KernelError::InvalidInput(
                format!("span must be positive, got {} m", ir.span_m()),
            ));
        }
        match &ir.section {
            SectionParams::PscI(p)  => psc_i_extrude(p, ir.span_mm()),
            // Other sections: fall back to PureRustKernel until implemented
            _ => {
                log::warn!(
                    "OcctKernel: section {:?} not yet implemented, using PureRust fallback",
                    ir.section_type
                );
                crate::psc_i::build_psc_i_mesh(
                    match &ir.section {
                        SectionParams::PscI(p) => p,
                        _ => unreachable!(),
                    },
                    ir.span_mm(),
                )
            }
        }
    }

    fn psc_i_extrude(p: &PscISectionParams, span_mm: f64) -> Result<Mesh, KernelError> {
        let hw   = p.top_flange_width    / 2.0;
        let hbw  = p.bottom_flange_width / 2.0;
        let hwb  = p.web_thickness       / 2.0;
        let h    = p.total_height;
        let tft  = p.top_flange_thickness;
        let bft  = p.bottom_flange_thickness;
        let hch  = p.haunch;

        // PSC-I 14-vertex profile in XY plane (mm), CCW
        let wire = Workplane::xy()
            .sketch()
            .move_to(-hbw,             0.0          )
            .line_to( hbw,             0.0          )
            .line_to( hbw,             bft          )
            .line_to( hwb,             bft          )
            .line_to( hwb,         h - tft - hch    )
            .line_to( hwb + hch,   h - tft          )
            .line_to( hw,          h - tft          )
            .line_to( hw,          h                )
            .line_to(-hw,          h                )
            .line_to(-hw,          h - tft          )
            .line_to(-(hwb + hch), h - tft          )
            .line_to(-hwb,         h - tft - hch    )
            .line_to(-hwb,             bft          )
            .line_to(-hbw,             bft          )
            .close()
            .to_face();

        // Extrude along Z axis by span_mm
        let solid = wire.extrude(DVec3::new(0.0, 0.0, span_mm));

        // Tessellate with engineering-grade tolerance (1 mm)
        let shape = solid.into();
        let occt_mesh = Mesher::try_new(&shape, 1.0)
            .map_err(|e| KernelError::Computation(format!("OCCT mesher init: {e}")))?
            .mesh()
            .map_err(|e| KernelError::Computation(format!("OCCT tessellation: {e}")))?;

        occt_mesh_to_cimery(occt_mesh)
    }

    // ── Other features (use PureRustKernel geometry for now) ─────────────────────

    pub fn deck_slab_mesh(ir: &DeckSlabIR) -> Result<Mesh, KernelError> {
        crate::deck_slab::build_deck_slab_mesh(ir)
    }

    pub fn bearing_mesh(ir: &BearingIR) -> Result<Mesh, KernelError> {
        crate::bearing::build_bearing_mesh(ir)
    }

    pub fn pier_mesh(ir: &PierIR) -> Result<Mesh, KernelError> {
        crate::pier::build_pier_mesh(ir)
    }

    pub fn abutment_mesh(ir: &AbutmentIR) -> Result<Mesh, KernelError> {
        crate::abutment::build_abutment_mesh(ir)
    }

    // ── Conversion ────────────────────────────────────────────────────────────────

    fn occt_mesh_to_cimery(m: opencascade::mesh::Mesh) -> Result<Mesh, KernelError> {
        if m.vertices.is_empty() {
            return Err(KernelError::Computation(
                "OCCT tessellation produced no vertices".into(),
            ));
        }

        let vertices: Vec<[f32; 3]> = m.vertices.iter()
            .map(|v| [v.x as f32, v.y as f32, v.z as f32])
            .collect();

        // normals array may be shorter (known OCCT API quirk, see mesh.rs)
        let normals: Vec<[f32; 3]> = if m.normals.len() == vertices.len() {
            m.normals.iter()
                .map(|n| {
                    let len = (n.x*n.x + n.y*n.y + n.z*n.z).sqrt();
                    if len < 1e-10 {
                        [0.0, 1.0, 0.0]
                    } else {
                        [(n.x/len) as f32, (n.y/len) as f32, (n.z/len) as f32]
                    }
                })
                .collect()
        } else {
            // Fallback: flat normals per vertex (less ideal but correct)
            vec![[0.0_f32, 1.0, 0.0]; vertices.len()]
        };

        let indices: Vec<u32> = m.indices.iter()
            .map(|&i| i as u32)
            .collect();

        let colors = vec![crate::COLOR_CONCRETE; vertices.len()];
        Ok(Mesh { vertices, normals, indices, colors })
    }
}

// ── Public struct (only when feature is active) ────────────────────────────────

#[cfg(feature = "occt")]
pub use self::occt_kernel::OcctKernel;

#[cfg(feature = "occt")]
mod occt_kernel {
    use cimery_ir::{AbutmentIR, BearingIR, DeckSlabIR, GirderIR, PierIR};
    use crate::{GeomKernel, KernelError, Mesh};
    use super::inner;

    /// Full B-rep geometry backend using OpenCASCADE Technology.
    /// Enabled with `--features occt`. See ADR-001.
    pub struct OcctKernel;

    impl GeomKernel for OcctKernel {
        fn girder_mesh(&self, ir: &GirderIR) -> Result<Mesh, KernelError> {
            inner::girder_mesh(ir)
        }
        fn deck_slab_mesh(&self, ir: &DeckSlabIR) -> Result<Mesh, KernelError> {
            inner::deck_slab_mesh(ir)
        }
        fn bearing_mesh(&self, ir: &BearingIR) -> Result<Mesh, KernelError> {
            inner::bearing_mesh(ir)
        }
        fn pier_mesh(&self, ir: &PierIR) -> Result<Mesh, KernelError> {
            inner::pier_mesh(ir)
        }
        fn abutment_mesh(&self, ir: &AbutmentIR) -> Result<Mesh, KernelError> {
            inner::abutment_mesh(ir)
        }
    }
}