- arc improvements, fillets, operations, bodys

2026-08-05 16:47:25 +02:00 · 2026-08-05 09:44:17 +02:00 · 2026-08-02 22:04:57 +02:00 · 2026-08-02 20:58:43 +02:00 · 2026-07-26 21:39:47 +02:00
17 changed files with 9926 additions and 2408 deletions
@@ -4,16 +4,22 @@
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+    <list default="true" id="8f0bafd6-58a0-4b20-aa2b-ddc3ba278873" name="Changes" comment="- arc improvements, fillets, operations, bodys">
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+      <change beforePath="$PROJECT_DIR$/src/fluency/ui/sketch_widget.py" beforeDir="false" afterPath="$PROJECT_DIR$/src/fluency/ui/sketch_widget.py" afterDir="false" />
+      <change beforePath="$PROJECT_DIR$/src/fluency/ui/viewer_widget.py" beforeDir="false" afterPath="$PROJECT_DIR$/src/fluency/ui/viewer_widget.py" afterDir="false" />
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@@ -30,7 +36,7 @@
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+        <entry key="$PROJECT_DIR$" value="feature/surface-modifier-pyramid-patterns" />
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-      <recent name="$PROJECT_DIR$/src/fluency/rendering" />
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+      <recent name="$PROJECT_DIR$/src/fluency/rendering" />
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@@ -442,7 +450,39 @@
      <option name="project" value="LOCAL" />
      <updated>1783976498520</updated>
    </task>
-    <option name="localTasksCounter" value="41" />
+    <task id="LOCAL-00041" summary="- added &quot;measurement lines&quot;">
+      <option name="closed" value="true" />
+      <created>1785094789247</created>
+      <option name="number" value="00041" />
+      <option name="presentableId" value="LOCAL-00041" />
+      <option name="project" value="LOCAL" />
+      <updated>1785094789248</updated>
+    </task>
+    <task id="LOCAL-00042" summary="- added &quot;measurement lines&quot;">
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+      <created>1785697123545</created>
+      <option name="number" value="00042" />
+      <option name="presentableId" value="LOCAL-00042" />
+      <option name="project" value="LOCAL" />
+      <updated>1785697123545</updated>
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+      <option name="closed" value="true" />
+      <created>1785701099363</created>
+      <option name="number" value="00043" />
+      <option name="presentableId" value="LOCAL-00043" />
+      <option name="project" value="LOCAL" />
+      <updated>1785701099363</updated>
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+      <option name="presentableId" value="LOCAL-00044" />
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@@ -463,8 +503,6 @@
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      <path value="$PROJECT_DIR$/pythonProject" />
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-    <MESSAGE value="- Sketch projection partly works again :)" />
-    <MESSAGE value="- Added new componnt controls" />
    <MESSAGE value="- changing compos for sketches works" />
    <MESSAGE value="- changing compos including sketches and bodies" />
    <MESSAGE value="- Drawing bodys depending on the selected compo&#10;- Cut working&#10;- Edit sketch working" />
@@ -488,6 +526,8 @@
    <MESSAGE value="-  added renderer" />
    <MESSAGE value="-  added renderer&#10;- Added undo" />
    <MESSAGE value="- Render improvements, camera plane, update" />
-    <option name="LAST_COMMIT_MESSAGE" value="- Render improvements, camera plane, update" />
+    <MESSAGE value="- added &quot;measurement lines&quot;" />
+    <MESSAGE value="- arc improvements, fillets, operations, bodys" />
+    <option name="LAST_COMMIT_MESSAGE" value="- arc improvements, fillets, operations, bodys" />
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 </project>
@@ -5,6 +5,7 @@ This module provides a concrete implementation of the geometry kernel
 using OCP (OpenCASCADE Python bindings).
 """

+import logging
 from typing import List, Tuple, Optional, Any, Dict
 import numpy as np

@@ -15,6 +16,8 @@ from fluency.geometry.base import (
    Point3D,
 )

+logger = logging.getLogger(__name__)
+

 class OCCGeometryObject(GeometryObject):
    """Geometry object wrapper for OpenCASCADE shapes."""
@@ -75,7 +78,7 @@ class OCGeometryKernel(GeometryKernel):
        return OCCGeometryObject(edge, {"type": "circle"})

    def create_arc(
-        self, center: Point2D, radius: float, start_angle: float, end_angle: float
+        self, center: Point2D, radius: float , start_angle: float, end_angle: float
    ) -> GeometryObject:
        """Create a 2D arc."""
        import math
@@ -235,6 +238,93 @@ class OCGeometryKernel(GeometryKernel):
            pass
        return None

+    @staticmethod
+    def find_coplanar_face(
+        shape: Any,
+        origin: Tuple[float, float, float],
+        normal: Tuple[float, float, float],
+        ref_center: Optional[Tuple[float, float, float]] = None,
+        angle_tol_deg: float = 5.0,
+        dist_tol: float = 1e-3,
+    ) -> Optional[Tuple[Any, Tuple[float, float, float]]]:
+        """Find a planar face on *shape* coplanar with the given plane.
+
+        Iterates the faces of *shape* and returns the first planar face whose
+        plane normal is parallel to *normal* (within *angle_tol_deg* degrees)
+        and whose plane passes through *origin* (within *dist_tol* distance).
+        When several faces match, the one whose surface centre is closest to
+        *ref_center* (if provided) is preferred.
+
+        Returns ``(face, center)`` where *center* is the surface centroid as a
+        3-tuple, or *None* if no matching face is found.
+        """
+        import math
+
+        from OCP.TopExp import TopExp_Explorer
+        from OCP.TopAbs import TopAbs_FACE
+        from OCP.TopoDS import TopoDS
+        from OCP.BRepAdaptor import BRepAdaptor_Surface
+        from OCP.GeomAbs import GeomAbs_Plane
+        from OCP.BRepGProp import BRepGProp
+        from OCP.GProp import GProp_GProps
+
+        import numpy as np
+
+        if shape is None:
+            return None
+        n = np.asarray(normal, dtype=float)
+        n = n / (np.linalg.norm(n) + 1e-30)
+        ox, oy, oz = origin
+
+        cos_tol = math.cos(math.radians(angle_tol_deg))
+        candidates: list = []
+
+        explorer = TopExp_Explorer(shape, TopAbs_FACE)
+        while explorer.More():
+            face = TopoDS.Face_s(explorer.Current())
+            try:
+                surf = BRepAdaptor_Surface(face)
+                if surf.GetType() != GeomAbs_Plane:
+                    explorer.Next()
+                    continue
+                plane = surf.Plane()
+                pn = np.array(
+                    [
+                        plane.Axis().Direction().X(),
+                        plane.Axis().Direction().Y(),
+                        plane.Axis().Direction().Z(),
+                    ],
+                    dtype=float,
+                )
+                # Check normals parallel (same or opposite direction)
+                cos_angle = abs(float(np.dot(n, pn)))
+                if cos_angle < cos_tol:
+                    explorer.Next()
+                    continue
+                # Check distance from plane to origin
+                pp = plane.Location()
+                d = abs(float(np.dot(n, np.array([pp.X() - ox, pp.Y() - oy, pp.Z() - oz]))))
+                if d > dist_tol:
+                    explorer.Next()
+                    continue
+                # Surface centroid via GProp (SurfaceProperties for faces)
+                props = GProp_GProps()
+                BRepGProp.SurfaceProperties_s(face, props)
+                c = props.CentreOfMass()
+                center = (float(c.X()), float(c.Y()), float(c.Z()))
+                candidates.append((face, center))
+            except Exception:
+                pass
+            explorer.Next()
+
+        if not candidates:
+            return None
+        if ref_center is not None and len(candidates) > 1:
+            rc = np.asarray(ref_center, dtype=float)
+            best = min(candidates, key=lambda fc: float(np.linalg.norm(np.asarray(fc[1]) - rc)))
+            return best
+        return candidates[0]
+
    def revolve(
        self,
        sketch: GeometryObject,
@@ -368,10 +458,11 @@ class OCGeometryKernel(GeometryKernel):
        else:
            from OCP.TopExp import TopExp_Explorer
            from OCP.TopAbs import TopAbs_EDGE
+            from OCP.TopoDS import TopoDS

            explorer = TopExp_Explorer(shape, TopAbs_EDGE)
            while explorer.More():
-                fillet.Add(radius, explorer.Current())
+                fillet.Add(radius, TopoDS.Edge_s(explorer.Current()))
                explorer.Next()

        fillet.Build()
@@ -392,10 +483,11 @@ class OCGeometryKernel(GeometryKernel):
        else:
            from OCP.TopExp import TopExp_Explorer
            from OCP.TopAbs import TopAbs_EDGE
+            from OCP.TopoDS import TopoDS

            explorer = TopExp_Explorer(shape, TopAbs_EDGE)
            while explorer.More():
-                chamfer.Add(size, explorer.Current())
+                chamfer.Add(size, TopoDS.Edge_s(explorer.Current()))
                explorer.Next()

        chamfer.Build()
@@ -488,6 +580,67 @@ class OCGeometryKernel(GeometryKernel):

        return OCCGeometryObject(transformer.Shape(), {"type": "mirrored"})

+    def pattern(
+        self,
+        body: GeometryObject,
+        pattern_type: str = "linear",
+        count: int = 2,
+        direction: Tuple[float, float, float] = (1, 0, 0),
+        spacing: float = 10.0,
+        axis: Tuple[float, float, float] = (0, 0, 1),
+        origin: Tuple[float, float, float] = (0.0, 0.0, 0.0),
+        angle: float = 360.0,
+    ) -> GeometryObject:
+        """Repeat *body* in a linear or circular array (pattern).
+
+        Linear: *count* copies spaced *spacing* mm apart along
+        *direction* (a negative spacing reverses the direction).
+
+        Circular: *count* copies rotated evenly around *axis* passing
+        through *origin*, distributed over a total angular span of
+        *angle* degrees (step = angle / count).  ``angle=360`` gives the
+        classic evenly-spaced full-circle bolt pattern.
+
+        Returns the union (compound when the copies don't touch) of the
+        original solid and all its copies — disjoint copies keep their
+        separate volumes inside one result object, touching copies fuse.
+        """
+        count = max(1, int(count))
+        if count <= 1:
+            return body
+
+        import math as _math
+
+        instances: list = [body]
+        if pattern_type == "circular":
+            # Normalize the rotation axis.
+            ax = float(axis[0]), float(axis[1]), float(axis[2])
+            norm = _math.sqrt(ax[0] * ax[0] + ax[1] * ax[1] + ax[2] * ax[2])
+            if norm < 1e-12:
+                ax = (0.0, 0.0, 1.0)
+            else:
+                ax = (ax[0] / norm, ax[1] / norm, ax[2] / norm)
+            step = _math.radians(float(angle)) / count
+            for i in range(1, count):
+                instances.append(self.rotate(body, ax, step * i, origin))
+        else:
+            d = float(direction[0]), float(direction[1]), float(direction[2])
+            norm = _math.sqrt(d[0] * d[0] + d[1] * d[1] + d[2] * d[2])
+            if norm < 1e-12:
+                d = (1.0, 0.0, 0.0)
+            else:
+                d = (d[0] / norm, d[1] / norm, d[2] / norm)
+            step = float(spacing)
+            for i in range(1, count):
+                instances.append(
+                    self.translate(
+                        body,
+                        (d[0] * step * i, d[1] * step * i, d[2] * step * i),
+                    )
+                )
+
+        return self.boolean_union(*instances)
+
    def export_step(self, body: GeometryObject, filepath: str, schema: str = "AP214") -> bool:
        """Export to STEP format."""
        try:
@@ -780,3 +933,363 @@ class OCGeometryKernel(GeometryKernel):

        cg = props.CentreOfMass()
        return Point3D(cg.X(), cg.Y(), cg.Z())
+
+    def create_thread(
+        self,
+        body: GeometryObject,
+        cylindrical_face: Any,
+        nominal_diameter: float,
+        pitch: float,
+        thread_length: Optional[float] = None,
+        internal: bool = False,
+    ) -> Optional[GeometryObject]:
+        """Cut (or add) an ISO metric thread on the cylindrical face of *body*.
+
+        The geometry is driven by the PICKED face's actual radius and axis
+        (``nominal_diameter`` is only metadata used for the feature record).
+        External threads cut the ISO groove trapezoid (7P/8 at the surface,
+        P/4 at the root, 5H/8 deep) out of the shaft; internal threads fuse
+        the ISO ridge trapezoid (3P/4 at the wall, P/8 crest) into the hole.
+        """
+        import math
+
+        from OCP.BRepAdaptor import BRepAdaptor_Surface
+        from OCP.GeomAbs import GeomAbs_Cylinder
+        from OCP.TopoDS import TopoDS
+        from OCP.gp import gp_Pnt, gp_Pnt2d, gp_Dir2d
+        from OCP.BRepBuilderAPI import (
+            BRepBuilderAPI_MakeEdge,
+            BRepBuilderAPI_MakeWire,
+        )
+
+        # ── 1. Cylinder parameters from the picked face ─────────────────
+        try:
+            surf = BRepAdaptor_Surface(cylindrical_face)
+        except Exception:
+            try:
+                surf = BRepAdaptor_Surface(TopoDS.Face_s(cylindrical_face))
+            except Exception as exc:
+                logger.warning(f"create_thread: cannot adapt face: {exc}")
+                return None
+
+        if surf.GetType() != GeomAbs_Cylinder:
+            logger.warning("create_thread: face is not cylindrical")
+            return None
+
+        cyl = surf.Cylinder()                       # gp_Cylinder
+        radius = cyl.Radius()                       # ACTUAL picked radius
+        ax3 = cyl.Position()                        # gp_Ax3 (location, Z, X)
+        loc = ax3.Location()
+        zdir = ax3.Direction()
+        xdir = ax3.XDirection()
+        axis_origin = np.array([loc.X(), loc.Y(), loc.Z()])
+        axis_dir = np.array([zdir.X(), zdir.Y(), zdir.Z()])
+        axis_dir = axis_dir / np.linalg.norm(axis_dir)
+        axis_x = np.array([xdir.X(), xdir.Y(), xdir.Z()])
+        axis_x = axis_x / np.linalg.norm(axis_x)
+        axis_y = np.cross(axis_dir, axis_x)
+
+        u_start = surf.FirstUParameter()            # angular start of face
+        v1, v2 = surf.FirstVParameter(), surf.LastVParameter()
+        v_lo, v_hi = min(v1, v2), max(v1, v2)
+        face_height = v_hi - v_lo
+
+        if not thread_length or thread_length <= 0:
+            thread_length = face_height
+        thread_length = min(thread_length, face_height)
+
+        num_turns = thread_length / pitch
+        if num_turns < 0.05:
+            logger.warning("create_thread: thread too short for one turn")
+            return None
+
+        # ── 2. ISO metric profile dimensions ────────────────────────────
+        # Basic profile (H = P·√3/2, thread engagement depth 5H/8):
+        #  • external shaft: groove cut is a trapezoid 7P/8 wide at the
+        #    surface narrowing to P/4 at the root.
+        #  • internal hole:  ridge fused onto the wall is a trapezoid 3P/4
+        #    wide at the wall narrowing to P/8 at the inner crest, leaving
+        #    the 7P/8-wide groove open at the bore.
+        H = pitch * math.sqrt(3.0) / 2.0
+        depth = (5.0 / 8.0) * H
+        overcut = max(0.1 * depth, 0.02)            # overhang past the surface
+        if internal:
+            w_surf = 3.0 * pitch / 4.0
+            w_deep = pitch / 8.0
+        else:
+            w_surf = 7.0 * pitch / 8.0
+            w_deep = pitch / 4.0
+
+        # ── 3. Helix spine ON the picked cylinder's surface ─────────────
+        # The swept profile sits in the helix's normal plane, tilted by the
+        # lead angle; its end caps therefore stick out past the spine ends
+        # by roughly half the profile width along the axis.  For a CUT that
+        # is harmless (the groove simply runs to the part edge), but a FUSE
+        # would leave the protruding cap as floating material outside the
+        # part, so inset the internal helix by exactly that amount.
+        lead = math.atan2(pitch, 2.0 * math.pi * radius)
+        cap_axial = (w_surf / 2.0) * math.cos(lead)  # cap half-extent along axis
+
+        if internal:
+            v_start = v_lo + cap_axial
+            v_end = min(v_lo + thread_length, v_hi) - cap_axial
+        else:
+            # extend one pitch past each face end so the groove runs off
+            # the part edges cleanly
+            v_start = v_lo - pitch
+            v_end = min(v_lo + thread_length + pitch, v_hi + pitch)
+        thread_span = v_end - v_start
+        if thread_span < 0.5 * pitch:
+            logger.warning("create_thread: part too short for a thread")
+            return None
+        turns_ext = thread_span / pitch
+
+        spine_wire = None
+
+        # 3a. TRUE helix: a 2D straight line on the cylinder surface.
+        #
+        # NOTE 1: gp_Dir2d NORMALIZES its argument, so the 2D line
+        # parameter t advances the point by t·|(2π, pitch)| in (u, v)
+        # space — scale the trim range so t = n turns covers exactly
+        # n revolutions plus n·pitch of axial travel.
+        # NOTE 2: the edge from a pcurve has no 3D curve; the pipe sweep
+        # needs one, so force it with BRepLib.BuildCurves3d.
+        spine_wire = None
+        try:
+            from OCP.Geom import Geom_CylindricalSurface
+            from OCP.Geom2d import Geom2d_Line, Geom2d_TrimmedCurve
+            from OCP.BRepLib import BRepLib
+
+            dir_len = math.hypot(2.0 * math.pi, pitch)
+            cyl_surf = Geom_CylindricalSurface(cyl)
+            line2d = Geom2d_Line(
+                gp_Pnt2d(u_start, v_start), gp_Dir2d(2.0 * math.pi, pitch)
+            )
+            seg = Geom2d_TrimmedCurve(line2d, 0.0, turns_ext * dir_len)
+            helix_edge = BRepBuilderAPI_MakeEdge(seg, cyl_surf).Edge()
+            BRepLib.BuildCurves3d_s(helix_edge)
+            spine_wire = BRepBuilderAPI_MakeWire(helix_edge).Wire()
+            logger.info("create_thread: using exact helix spine")
+        except Exception as exc:
+            logger.info(f"create_thread: exact helix failed ({exc})")
+
+        # 3b. Fallback: smooth BSpline through sampled helix points
+        # (only if the exact construction is unavailable).
+        if spine_wire is None:
+            try:
+                from OCP.GeomAPI import GeomAPI_PointsToBSpline
+                from OCP.TColgp import TColgp_Array1OfPnt
+                from OCP.GeomAbs import GeomAbs_C2
+
+                pts_per_turn = 96
+                n_total = max(int(turns_ext * pts_per_turn) + 1, 2)
+                arr = TColgp_Array1OfPnt(1, n_total)
+                for i in range(1, n_total + 1):
+                    u = u_start + ((i - 1) / pts_per_turn) * 2.0 * math.pi
+                    v = v_start + ((i - 1) / pts_per_turn) * pitch
+                    p = (
+                        axis_origin
+                        + radius * (math.cos(u) * axis_x + math.sin(u) * axis_y)
+                        + v * axis_dir
+                    )
+                    arr.SetValue(i, gp_Pnt(float(p[0]), float(p[1]), float(p[2])))
+                bspline = GeomAPI_PointsToBSpline(arr, 3, 8, GeomAbs_C2, 1e-5)
+                bs_edge = BRepBuilderAPI_MakeEdge(bspline.Curve()).Edge()
+                spine_wire = BRepBuilderAPI_MakeWire(bs_edge).Wire()
+                logger.info("create_thread: using BSpline helix fallback")
+            except Exception as exc:
+                logger.warning(f"create_thread: BSpline helix failed ({exc})")
+
+        if spine_wire is None:
+            logger.warning("create_thread: no usable helix spine")
+            return None
+
+        # Start frame (same for both spine types — computed analytically).
+        def _cyl_pt(u: float, v: float) -> np.ndarray:
+            return (
+                axis_origin
+                + radius * (math.cos(u) * axis_x + math.sin(u) * axis_y)
+                + v * axis_dir
+            )
+
+        start_S = _cyl_pt(u_start, v_start)
+        start_T = (
+            2.0 * math.pi * radius
+            * (-math.sin(u_start) * axis_x + math.cos(u_start) * axis_y)
+            + pitch * axis_dir
+        )
+        start_T = start_T / np.linalg.norm(start_T)
+        start_R = math.cos(u_start) * axis_x + math.sin(u_start) * axis_y  # outward
+
+        # Profile width direction: perpendicular to tangent in the surface
+        # plane (≈ axial direction).  Trapezoid is symmetric so sign is fine.
+        binormal = np.cross(start_T, start_R)
+        binormal = binormal / np.linalg.norm(binormal)
+
+        # ── 4. Trapezoidal profile at the spine start ───────────────────
+        # Built directly in world coords: base sits *overcut* OUTSIDE the
+        # surface so the boolean fuses/cuts cleanly across it; the working
+        # end reaches *depth* INSIDE the surface.
+        def _mk(b: float, r: float) -> gp_Pnt:
+            p = start_S + b * binormal + r * start_R
+            return gp_Pnt(float(p[0]), float(p[1]), float(p[2]))
+
+        p0 = _mk(-w_surf / 2.0, overcut)
+        p1 = _mk(-w_deep / 2.0, -depth)
+        p2 = _mk(+w_deep / 2.0, -depth)
+        p3 = _mk(+w_surf / 2.0, overcut)
+
+        prof_wb = BRepBuilderAPI_MakeWire()
+        for a, b in ((p0, p1), (p1, p2), (p2, p3), (p3, p0)):
+            prof_wb.Add(BRepBuilderAPI_MakeEdge(a, b).Edge())
+        profile_wire = prof_wb.Wire()
+
+        # ── 5. Sweep the profile along the helix ────────────────────────
+        from OCP.BRepOffsetAPI import BRepOffsetAPI_MakePipeShell
+
+        try:
+            pipe = BRepOffsetAPI_MakePipeShell(spine_wire)
+            pipe.SetMode(True)                       # Frenet frame
+            pipe.Add(profile_wire, False, False)
+            pipe.Build()
+            if not pipe.IsDone():
+                logger.warning("create_thread: pipe sweep failed")
+                return None
+            solid_ok = False
+            try:
+                solid_ok = bool(pipe.MakeSolid())    # cap the tube ends
+            except Exception as exc:
+                logger.info(f"create_thread: MakeSolid unavailable ({exc})")
+            tool_shape = pipe.Shape()
+            if not solid_ok:
+                logger.warning("create_thread: sweep is not a solid")
+        except Exception as exc:
+            logger.warning(f"create_thread: sweep failed: {exc}")
+            return None
+
+        # ── 6. Boolean cut (shaft) or fuse (hole) ───────────────────────
+        body_shape = self._get_shape(body)
+        if body_shape is None:
+            logger.warning("create_thread: body has no shape")
+            return None
+
+        tool = OCCGeometryObject(tool_shape)
+        vol_before = self.get_volume(body)
+
+        if internal:
+            result = self.boolean_union(body, tool)
+        else:
+            result = self.boolean_difference(body, tool)
+
+        if result is None or self._get_shape(result) is None:
+            logger.warning("create_thread: boolean op produced no shape")
+            return None
+
+        try:
+            vol_after = self.get_volume(result)
+        except Exception:
+            vol_after = -1.0
+
+        if internal and vol_after <= vol_before:
+            logger.warning(
+                f"create_thread: fuse did not add volume "
+                f"({vol_before:.4f} → {vol_after:.4f}) — tool missed the body?"
+            )
+            return None
+        if not internal and vol_after >= vol_before:
+            logger.warning(
+                f"create_thread: cut did not remove volume "
+                f"({vol_before:.4f} → {vol_after:.4f}) — tool missed the body?"
+            )
+            return None
+
+        logger.info(
+            f"create_thread: {'internal' if internal else 'external'} thread OK, "
+            f"volume {vol_before:.4f} → {vol_after:.4f}"
+        )
+        return result
+
+    def detect_cylindrical_face(
+        self,
+        face: Any,
+    ) -> Optional[Dict[str, Any]]:
+        """Check if *face* is cylindrical and return its parameters.
+
+        The *face* can be a ``TopoDS_Face`` (from the picker) or a
+        ``TopoDS_Shape`` that contains a face.  We try several paths to
+        extract the underlying cylindrical surface.
+
+        Returns a dict with keys ``radius``, ``axis_origin``, ``axis_dir``,
+        ``height``, or *None* if the face isn't cylindrical.
+        """
+        import logging
+        import numpy as np
+        from OCP.BRepAdaptor import BRepAdaptor_Surface
+        from OCP.GeomAbs import GeomAbs_Cylinder
+        from OCP.TopoDS import TopoDS
+
+        _log = logging.getLogger(__name__)
+
+        # ── Resolve the actual face from whatever the caller handed us ──
+        actual_face: Any = None
+
+        # Try direct BRepAdaptor_Surface first — the picker already returns
+        # a valid TopoDS_Face, and calling TopoDS.Face_s() again on an
+        # already-downcast face can fail in some OCP versions.
+        try:
+            surf = BRepAdaptor_Surface(face)
+            surf_type_test = surf.GetType()
+            actual_face = face
+        except Exception:
+            pass
+
+        if actual_face is None:
+            # Fallback: try the explicit TopoDS.Face_s downcast path.
+            try:
+                candidate = TopoDS.Face_s(face)
+                _ = BRepAdaptor_Surface(candidate)
+                actual_face = candidate
+            except Exception:
+                pass
+
+        if actual_face is None:
+            _log.warning("detect_cylindrical_face: could not resolve face from pick result")
+            return None
+
+        # ── Probe the surface type ──
+        try:
+            surf = BRepAdaptor_Surface(actual_face)
+            surf_type = surf.GetType()
+            if surf_type != GeomAbs_Cylinder:
+                type_names = {
+                    0: "Plane", 1: "Cylinder", 2: "Cone", 3: "Sphere",
+                    4: "Torus", 5: "Bezier", 6: "BSpline", 7: "Revolution",
+                    8: "Extrusion", 9: "Offset", 10: "Other",
+                }
+                type_name = type_names.get(int(surf_type), f"Unknown({int(surf_type)})")
+                _log.warning(
+                    f"detect_cylindrical_face: face is {type_name}, not a Cylinder"
+                )
+                return None
+
+            cyl = surf.Cylinder()
+            radius = cyl.Radius()
+            axis = cyl.Axis()
+            origin = axis.Location()
+            direction = axis.Direction()
+            # BRepAdaptor_Surface uses FirstUParameter/LastUParameter etc.
+            u1 = surf.FirstUParameter()
+            u2 = surf.LastUParameter()
+            v1 = surf.FirstVParameter()
+            v2 = surf.LastVParameter()
+            height = abs(v2 - v1)
+            return {
+                "radius": radius,
+                "diameter": 2.0 * radius,
+                "axis_origin": (origin.X(), origin.Y(), origin.Z()),
+                "axis_dir": (direction.X(), direction.Y(), direction.Z()),
+                "height": height,
+            }
+        except Exception as exc:
+            _log.warning(f"detect_cylindrical_face: surface probe failed: {exc}")
+            return None
@@ -0,0 +1,385 @@
+"""Surface modifier for OpenCASCADE geometry.
+
+Applies geometric patterns (pyramids, bumps, grooves) to 3D surfaces using boolean operations.
+This enables grip-enhancing textures and visual surface modifications on CAD models.
+"""
+
+from __future__ import annotations
+
+import logging
+import math
+from typing import Any, Optional, Tuple
+
+# OCC imports at module level for common types
+
+
+logger = logging.getLogger(__name__)
+
+
+class SurfaceModifier:
+    """Applies geometric patterns to 3D surfaces using OCC boolean operations."""
+
+    def __init__(self):
+        self._patterns_applied = []
+
+    def apply_pyramid_pattern(
+        self,
+        face_shape,
+        pyramid_height: float = 1.0,
+        base_radius: float = 2.0,
+        spacing: float = 5.0,
+        num_rings: Optional[int] = None,
+        direction: Tuple[float, float, float] = (0, 0, 1),
+    ) -> Optional[Any]:
+        """Apply a pyramid pattern to a face surface.
+
+        Args:
+            face_shape: OCC TopoDS_Shape representing the face or solid
+            pyramid_height: Height of each pyramid
+            base_radius: Radius of pyramid base
+            spacing: Distance between pyramids
+            num_rings: Number of concentric rings (auto-calculated if None)
+            direction: Normal direction for pyramids
+
+        Returns:
+            Modified shape on success, None on failure
+        """
+        try:
+            from OCP.TopAbs import TopAbs_FACE
+            from OCP.TopoDS import TopoDS_Face, TopoDS_Shape
+            from OCP.BRepAlgoAPI import BRepAlgoAPI_Fuse
+            from OCP.TopExp import TopExp_Explorer
+            from OCP.BRepAdaptor import BRepAdaptor_Surface
+
+            # Validate face shape
+            if not isinstance(face_shape, (TopoDS_Shape, TopoDS_Face)):
+                logger.error("Invalid face shape type")
+                return None
+
+            # Extract the first face for surface parameterization
+            if isinstance(face_shape, TopoDS_Shape):
+                explorer = TopExp_Explorer(face_shape, TopAbs_FACE)
+                if not explorer.More():
+                    logger.error("No faces found in shape")
+                    return None
+                from OCP import TopoDS
+                face = TopoDS.TopoDS.Face_s(explorer.Current())
+            else:
+                face = face_shape
+
+            # Get face surface for UV parameterization
+            surf = BRepAdaptor_Surface(face)
+
+            u_min, u_max = surf.FirstUParameter(), surf.LastUParameter()
+            v_min, v_max = surf.FirstVParameter(), surf.LastVParameter()
+
+            # Calculate number of rings if not specified
+            if num_rings is None:
+                # Estimate based on face area and spacing
+                u_range = u_max - u_min
+                v_range = v_max - v_min
+                avg_dim = (u_range + v_range) / 2.0
+                num_rings = max(1, min(int(avg_dim / spacing), 5))
+
+            logger.info(
+                f"Applying pyramid pattern: {num_rings} rings, "
+                f"{base_radius:.2f} radius, {pyramid_height:.2f} height"
+            )
+
+            # Create pyramids distributed across the face UV space
+            result_shape = face_shape
+            pyramid_count = 0
+
+            for ring_idx in range(num_rings):
+                # Distribute rings evenly across UV parameter space
+                u_fraction = (ring_idx + 1) / (num_rings + 1)
+                v_fraction = 0.5  # Center vertically
+
+                # Map to actual UV coordinates on the face
+                u_pos = u_min + u_fraction * (u_max - u_min)
+                v_pos = v_min + v_fraction * (v_max - v_min)
+
+                # Get 3D position and tangent vectors at this UV point
+                from OCP.gp import gp_Pnt, gp_Vec
+
+                center_pt = gp_Pnt()
+                d1u = gp_Vec()
+                d1v = gp_Vec()
+                surf.D1(u_pos, v_pos, center_pt, d1u, d1v)
+                # Normal is cross product of tangent vectors
+                normal = d1u.Crossed(d1v)
+                normal.Normalize()
+
+                # Calculate number of pyramids in this ring based on spacing
+                if ring_idx == 0:
+                    num_pyramids = 1  # Center pyramid
+                else:
+                    circumference = 2.0 * math.pi * (ring_idx * spacing)
+                    num_pyramids = max(3, int(circumference / spacing))
+
+                for i in range(num_pyramids):
+                    if ring_idx == 0:
+                        # Center pyramid - place at face center
+                        place_u = u_pos
+                        place_v = v_pos
+                    else:
+                        angle = (2.0 * math.pi * i) / num_pyramids
+                        # Offset in UV space based on ring radius
+                        offset_u = (ring_idx * spacing / (u_max - u_min)) * math.cos(angle)
+                        offset_v = (ring_idx * spacing / (v_max - v_min)) * math.sin(angle)
+                        place_u = max(u_min, min(u_max, u_pos + offset_u))
+                        place_v = max(v_min, min(v_max, v_pos + offset_v))
+
+                    try:
+                        # Get 3D position and normal for this pyramid
+                        pyramid_pt = gp_Pnt()
+                        pd1u = gp_Vec()
+                        pd1v = gp_Vec()
+                        surf.D1(place_u, place_v, pyramid_pt, pd1u, pd1v)
+                        pyramid_normal = pd1u.Crossed(pd1v)
+                        pyramid_normal.Normalize()
+
+                        # Create solid pyramid at this position
+                        pyramid_shape = self._create_solid_pyramid(
+                            pyramid_pt,
+                            pyramid_normal,
+                            pyramid_height,
+                            base_radius,
+                        )
+
+                        if pyramid_shape is not None:
+                            # Fuse with existing geometry
+                            fuse = BRepAlgoAPI_Fuse(result_shape, pyramid_shape)
+                            fuse.Build()
+
+                            if fuse.IsDone():
+                                result_shape = fuse.Shape()
+                                pyramid_count += 1
+                            else:
+                                logger.warning(
+                                    f"Failed to fuse pyramid at ({place_u:.2f}, {place_v:.2f})"
+                                )
+                    except Exception as e:
+                        logger.debug(
+                            f"Error creating pyramid at ring {ring_idx}, pyramid {i}: {e}"
+                        )
+
+            self._patterns_applied.append(
+                {
+                    "type": "pyramid",
+                    "parameters": {
+                        "height": pyramid_height,
+                        "base_radius": base_radius,
+                        "spacing": spacing,
+                        "num_rings": num_rings,
+                        "direction": direction,
+                    },
+                }
+            )
+
+            logger.info(f"Successfully applied {pyramid_count} pyramids")
+
+            return result_shape
+
+        except Exception as e:
+            logger.error(f"Error applying pyramid pattern: {e}", exc_info=True)
+            return None
+
+    def _create_solid_pyramid(
+        self,
+        base_point,  # gp_Pnt - position on the face
+        normal_vec,  # gp_Dir or gp_Vec - surface normal direction
+        height: float,
+        base_radius: float,
+    ) -> Optional[Any]:
+        """Create a solid pyramid at the specified position and orientation.
+
+        Uses BRepPrimAPI_MakePrism to extrude a square base into a solid pyramid.
+
+        Args:
+            base_point: 3D point where pyramid base is centered
+            normal_vec: Direction vector for pyramid growth (surface normal)
+            height: Height of the pyramid from base to apex
+            base_radius: Half-width of the square base
+
+        Returns:
+            OCC solid shape for the pyramid, or None on failure
+        """
+        try:
+            from OCP.gp import gp_Dir, gp_Ax2, gp_Vec
+            from OCP.BRepBuilderAPI import (
+                BRepBuilderAPI_MakeEdge,
+                BRepBuilderAPI_MakeWire,
+            )
+            from OCP.BRepPrimAPI import BRepPrimAPI_MakePrism
+
+            half = base_radius / 2.0
+
+            # Build orthonormal basis from normal vector
+            if isinstance(normal_vec, gp_Vec):
+                n_dir = gp_Dir(normal_vec.XYZ())
+            else:
+                n_dir = normal_vec
+
+            # Create a local coordinate system at the base point
+            local_ax2 = gp_Ax2(base_point, n_dir)
+
+            # Get X and Y axes from the local coordinate system
+            x_dir = local_ax2.XDirection()
+            y_dir = local_ax2.YDirection()
+
+            # Create 4 corners of the square base in the local plane
+            corner_points = [
+                base_point + gp_Vec(x_dir).Multiplied(half) + gp_Vec(y_dir).Multiplied(half),
+                base_point + gp_Vec(x_dir).Multiplied(-half) + gp_Vec(y_dir).Multiplied(half),
+                base_point + gp_Vec(x_dir).Multiplied(-half) + gp_Vec(y_dir).Multiplied(-half),
+                base_point + gp_Vec(x_dir).Multiplied(half) + gp_Vec(y_dir).Multiplied(-half),
+            ]
+
+            # Create edges connecting the corners
+            wire_maker = BRepBuilderAPI_MakeWire()
+            for idx in range(4):
+                next_idx = (idx + 1) % 4
+                edge = BRepBuilderAPI_MakeEdge(
+                    corner_points[idx], corner_points[next_idx]
+                ).Edge()
+                wire_maker.Add(edge)
+
+            if not wire_maker.IsDone():
+                logger.warning("Failed to create pyramid base wire")
+                return None
+
+            # Extrude the base wire in the normal direction by height to form a prism
+            extrusion_vec = gp_Vec(n_dir).Multiplied(height)
+            prism_maker = BRepPrimAPI_MakePrism(
+                wire_maker.Wire(), extrusion_vec, False  # no check intersection
+            )
+            prism_maker.Build()
+
+            if not prism_maker.IsDone():
+                logger.warning("Failed to create pyramid prism")
+                return None
+
+            return prism_maker.Shape()
+
+        except Exception as e:
+            logger.debug(f"Error creating solid pyramid: {e}")
+            return None
+
+    def apply_bump_pattern(
+        self,
+        face_shape,
+        bump_height: float = 1.0,
+        bump_radius: float = 2.0,
+        spacing: float = 5.0,
+        num_rings: Optional[int] = None,
+    ) -> Optional[Any]:
+        """Apply a simple bump pattern to a face surface.
+
+        Args:
+            face_shape: OCC TopoDS_Shape representing the face
+            bump_height: Height of each bump
+            bump_radius: Radius of each bump base
+            spacing: Distance between bumps
+            num_rings: Number of concentric rings
+
+        Returns:
+            Modified shape on success, None on failure
+        """
+        return self.apply_pyramid_pattern(
+            face_shape,
+            pyramid_height=bump_height,
+            base_radius=bump_radius,
+            spacing=spacing,
+            num_rings=num_rings,
+        )
+
+
+def apply_surface_modifier_to_body(
+    body_geometry, modifier_type: str = "pyramid", **parameters
+) -> Optional[Any]:
+    """Apply a surface modifier to a body geometry.
+
+    Args:
+        body_geometry: OCCGeometryObject or similar geometry object
+        modifier_type: Type of modifier ('pyramid', 'bump')
+        **parameters: Modifier-specific parameters
+
+    Returns:
+        Modified shape, or None on failure
+    """
+    from fluency.geometry_occ.kernel import OCGeometryKernel
+
+    kernel = OCGeometryKernel()
+    shape = kernel._get_shape(body_geometry)
+
+    if shape is None:
+        logger.error("No geometry found in body")
+        return None
+
+    modifier = SurfaceModifier()
+
+    try:
+        if modifier_type == "pyramid":
+            success = modifier.apply_pyramid_pattern(shape, **parameters)
+        elif modifier_type == "bump":
+            success = modifier.apply_bump_pattern(shape, **parameters)
+        else:
+            logger.error(f"Unknown modifier type: {modifier_type}")
+            return None
+
+        if not success:
+            logger.error("Surface modifier application failed")
+            return None
+
+        # Return the modified shape wrapped in OCCGeometryObject
+        from fluency.geometry_occ.kernel import OCCGeometryObject
+
+        return OCCGeometryObject(shape)
+
+    except Exception as e:
+        logger.error(f"Error applying surface modifier: {e}", exc_info=True)
+        return None
+
+
+# Example usage and testing
+if __name__ == "__main__":
+    # Create a simple test case
+    from OCP.BRepPrimAPI import BRepPrimAPI_MakeBox
+
+    # Create a box to modify
+    box_maker = BRepPrimAPI_MakeBox(50, 50, 10)
+    box_maker.Build()
+
+    if box_maker.IsDone():
+        print("Created test box")
+
+        # Apply pyramid pattern to top face (Z direction)
+        modifier = SurfaceModifier()
+        success = modifier.apply_pyramid_pattern(
+            box_maker.Shape(),
+            pyramid_height=2.0,
+            base_radius=3.0,
+            spacing=8.0,
+            num_rings=2,
+            direction=(0, 0, 1),
+        )
+
+        if success:
+            print("Successfully applied pyramid pattern")
+
+            # Export modified shape
+            from OCP.StlAPI import StlAPI_Writer
+            from OCP.BRepMesh import BRepMesh_IncrementalMesh
+
+            tess = BRepMesh_IncrementalMesh(box_maker.Shape(), 0.1)
+            tess.Perform()
+
+            writer = StlAPI_Writer()
+            writer.SetASCIIMode(False)
+            writer.Write(box_maker.Shape(), "/tmp/test_pyramid_pattern.stl")
+            print("Exported modified shape to STL")
+        else:
+            print("Failed to apply pyramid pattern")
+    else:
+        print("Failed to create test box")
@@ -28,6 +28,7 @@ import logging
 import os
 import shutil
 import tempfile
+import uuid
 import zipfile
 from dataclasses import asdict, is_dataclass
 from datetime import datetime
@@ -42,6 +43,7 @@ from fluency.models.data_model import (
    Body,
    Component,
    Connector,
+    Feature,
    Project,
    Sketch,
    Workplane,
@@ -65,7 +67,7 @@ def _json_default(obj: Any) -> Any:
        return sorted(obj)
    if isinstance(obj, tuple):
        return list(obj)
-    if is_dataclass(obj):
+    if is_dataclass(obj) and not isinstance(obj, type):
        return asdict(obj)
    raise TypeError(f"Object of type {type(obj).__name__} is not JSON serializable")

@@ -85,42 +87,77 @@ def _coerce_listlike(value: Any) -> List[Any]:
    return list(value)


+def _to_float(value: Any, default: float = 0.0) -> float:
+    """Safely coerce a saved value to float, falling back to *default*.
+
+    Corrupt archives may store a string or None where a number is expected;
+    the loaders must not crash on them.
+    """
+    try:
+        return float(value)
+    except (TypeError, ValueError):
+        return default
+
+
+def _saved_id(data: Dict[str, Any]) -> str:
+    """Return a saved entity id, or a fresh UUID for corrupt/legacy data.
+
+    Old files always wrote an ``id``; a missing/empty value means the
+    archive is damaged, and the model's uuid factory only kicks in when the
+    constructor argument is omitted — so we generate here to keep ids valid
+    non-empty strings.
+    """
+    v = data.get("id")
+    if isinstance(v, str) and v:
+        return v
+    return str(uuid.uuid4())
+
+
 def _to_3tuple(value: Any) -> Tuple[float, float, float]:
    """Coerce a saved 3-vector to a tuple of floats (for OCC)."""
    if value is None:
        return (0.0, 0.0, 0.0)
-    if isinstance(value, np.ndarray):
-        seq = value.tolist()
-    else:
-        seq = list(value)
-    if len(seq) < 3:
-        seq = list(seq) + [0.0] * (3 - len(seq))
-    return (float(seq[0]), float(seq[1]), float(seq[2]))
+    try:
+        if isinstance(value, np.ndarray):
+            seq = value.tolist()
+        else:
+            seq = list(value)
+        if len(seq) < 3:
+            seq = list(seq) + [0.0] * (3 - len(seq))
+        return (float(seq[0]), float(seq[1]), float(seq[2]))
+    except (TypeError, ValueError, IndexError):
+        return (0.0, 0.0, 0.0)


 def _to_3vec(value: Any) -> np.ndarray:
    """Coerce a saved 3-vector to a 3-element numpy array."""
-    if isinstance(value, np.ndarray):
-        return value.astype(float).reshape(3)
-    if value is None:
+    try:
+        if isinstance(value, np.ndarray):
+            return value.astype(float).reshape(3)
+        if value is None:
+            return np.zeros(3, dtype=float)
+        seq = list(value)
+        if len(seq) < 3:
+            seq = list(seq) + [0.0] * (3 - len(seq))
+        return np.array([float(seq[0]), float(seq[1]), float(seq[2])], dtype=float)
+    except (TypeError, ValueError, IndexError):
        return np.zeros(3, dtype=float)
-    seq = list(value)
-    if len(seq) < 3:
-        seq = list(seq) + [0.0] * (3 - len(seq))
-    return np.array([float(seq[0]), float(seq[1]), float(seq[2])], dtype=float)


 def _to_mat3(value: Any) -> np.ndarray:
    """Coerce a saved 3×3 matrix (flat 9-list or nested) to np.ndarray."""
-    if isinstance(value, np.ndarray):
-        arr = value.astype(float)
-        return arr.reshape(3, 3)
-    if value is None:
+    try:
+        if isinstance(value, np.ndarray):
+            arr = value.astype(float)
+            return arr.reshape(3, 3)
+        if value is None:
+            return np.eye(3, dtype=float)
+        flat = list(np.asarray(value, dtype=float).flatten())
+        if len(flat) < 9:
+            flat = flat + [0.0] * (9 - len(flat))
+        return np.array(flat[:9], dtype=float).reshape(3, 3)
+    except (TypeError, ValueError, IndexError):
        return np.eye(3, dtype=float)
-    flat = list(np.asarray(value, dtype=float).flatten())
-    if len(flat) < 9:
-        flat = flat + [0.0] * (9 - len(flat))
-    return np.array(flat[:9], dtype=float).reshape(3, 3)


 def _parse_iso(value: Optional[str]) -> datetime:
@@ -151,11 +188,11 @@ def _workplane_to_dict(wp: Workplane) -> Dict[str, Any]:

 def _workplane_from_dict(data: Dict[str, Any]) -> Workplane:
    wp = Workplane(
-        id=data.get("id") or None,  # Workplane generates uuid if None
+        id=_saved_id(data),
        name=data.get("name", "Untitled Workplane"),
-        origin=tuple(data.get("origin", (0.0, 0.0, 0.0))),
-        normal=tuple(data.get("normal", (0.0, 0.0, 1.0))),
-        x_dir=tuple(data.get("x_dir", (1.0, 0.0, 0.0))),
+        origin=_to_3tuple(data.get("origin", (0.0, 0.0, 0.0))),
+        normal=_to_3tuple(data.get("normal", (0.0, 0.0, 1.0))),
+        x_dir=_to_3tuple(data.get("x_dir", (1.0, 0.0, 0.0))),
        visible=bool(data.get("visible", True)),
    )
    wp.created_at = _parse_iso(data.get("created_at"))
@@ -163,6 +200,70 @@ def _workplane_from_dict(data: Dict[str, Any]) -> Workplane:
    return wp


+def _feature_to_dict(feat: Feature) -> Dict[str, Any]:
+    """Serialize one parametric feature (sketch id + params).
+
+    "base" snapshot features are NOT serialized here — their frozen
+    geometry is written as a separate STEP member (``base_geometry_ref``)
+    and the ``features_base_snapshot`` flag on the body marks that the
+    list starts with one.
+    """
+    return {
+        "id": feat.id,
+        "operation": feat.operation,
+        "sketch_id": feat.sketch.id if feat.sketch is not None else None,
+        "length": feat.length,
+        "symmetric": bool(feat.symmetric),
+        "invert": bool(feat.invert),
+        "through_all": bool(feat.through_all),
+        "cut_all_bodies": bool(feat.cut_all_bodies),
+        "face_index": feat.face_index,
+        "angle": _to_float(feat.angle, 360.0),
+        "axis": [float(v) for v in (feat.axis or (0, 0, 1))],
+        "origin": [float(v) for v in (feat.origin or (0.0, 0.0, 0.0))],
+        "axis_line_id": feat.axis_line_id,
+        "radius": feat.radius,
+        "tangent_propagation": bool(feat.tangent_propagation),
+        "scope": feat.scope,
+        "edge_refs": list(feat.edge_refs),
+        "pattern_type": feat.pattern_type,
+        "count": feat.count,
+        "spacing": feat.spacing,
+        "direction": [float(v) for v in (feat.direction or (1, 0, 0))],
+    }
+
+
+def _feature_from_dict(data: Dict[str, Any], sketches: Dict[str, Sketch]) -> Feature:
+    """Deserialize a feature, resolving its sketch reference against the
+    component's already-loaded sketches."""
+    feat = Feature(
+        id=_saved_id(data),
+        operation=data.get("operation", "extrude"),
+        length=data.get("length"),
+        symmetric=bool(data.get("symmetric", False)),
+        invert=bool(data.get("invert", False)),
+        through_all=bool(data.get("through_all", False)),
+        cut_all_bodies=bool(data.get("cut_all_bodies", False)),
+        face_index=data.get("face_index"),
+        angle=_to_float(data.get("angle"), 360.0),
+        axis=tuple(float(v) for v in (data.get("axis") or (0, 0, 1))),
+        origin=tuple(float(v) for v in (data.get("origin") or (0.0, 0.0, 0.0))),
+        axis_line_id=data.get("axis_line_id"),
+        radius=data.get("radius"),
+        tangent_propagation=bool(data.get("tangent_propagation", False)),
+        scope=data.get("scope", "selected"),
+        edge_refs=list(data.get("edge_refs") or []),
+        pattern_type=data.get("pattern_type", "linear"),
+        count=int(data.get("count") or 2),
+        spacing=_to_float(data.get("spacing"), 10.0),
+        direction=tuple(float(v) for v in (data.get("direction") or (1, 0, 0))),
+    )
+    sid = data.get("sketch_id")
+    if sid and sid in sketches:
+        feat.sketch = sketches[sid]
+    return feat
+
+
 def _body_to_dict(body: Body) -> Dict[str, Any]:
    """Body serialization.  ``geometry_ref`` is set later by the ZIP writer
    once the STEP file is written."""
@@ -177,12 +278,16 @@ def _body_to_dict(body: Body) -> Dict[str, Any]:
        "extrude_cut": body.extrude_cut,
        "extrude_union": body.extrude_union,
        "extrude_through_all": body.extrude_through_all,
+        "extrude_cut_all_bodies": body.extrude_cut_all_bodies,
        "extrude_face_index": body.extrude_face_index,
        "extrude_target_body_id": body.extrude_target_body_id,
+        "features": [_feature_to_dict(f) for f in body.features if f.operation != "base"],
+        "features_base_snapshot": bool(body.features and body.features[0].operation == "base"),
+        "base_geometry_ref": None,  # filled in by save_project
        "position": _coerce_listlike(body.position),
        "rotation": _coerce_listlike(body.rotation),
        "color": list(body.color) if body.color else [0.2, 0.4, 0.8],
-        "opacity": float(body.opacity),
+        "opacity": _to_float(body.opacity, 1.0),
        "visible": bool(body.visible),
        "has_geometry": body.geometry is not None,
        "geometry_ref": None,  # filled in by save_project
@@ -201,7 +306,7 @@ def _body_from_dict(
        geometry = geometry_loader(data["geometry_ref"]) if data.get("has_geometry") else None

    body = Body(
-        id=data.get("id") or None,
+        id=_saved_id(data),
        name=data.get("name", "Untitled Body"),
        geometry=geometry,
        source_sketch=source_sketch,
@@ -212,12 +317,13 @@ def _body_from_dict(
        extrude_cut=bool(data.get("extrude_cut", False)),
        extrude_union=bool(data.get("extrude_union", False)),
        extrude_through_all=bool(data.get("extrude_through_all", False)),
+        extrude_cut_all_bodies=bool(data.get("extrude_cut_all_bodies", False)),
        extrude_face_index=data.get("extrude_face_index"),
        extrude_target_body_id=data.get("extrude_target_body_id"),
        position=_to_3vec(data.get("position")),
        rotation=_to_mat3(data.get("rotation")),
        color=tuple(data.get("color", [0.2, 0.4, 0.8])),
-        opacity=float(data.get("opacity", 1.0)),
+        opacity=_to_float(data.get("opacity"), 1.0),
        visible=bool(data.get("visible", True)),
    )
    body.created_at = _parse_iso(data.get("created_at"))
@@ -267,9 +373,9 @@ def _sketch_from_dict(
    # Re-apply the workplane (from_dict already does this internally, but be
    # defensive in case the saved dict didn't carry the workplane fields).
    occ_sketch.set_workplane(
-        tuple(data.get("workplane_origin", (0.0, 0.0, 0.0))),
-        tuple(data.get("workplane_normal", (0.0, 0.0, 1.0))),
-        tuple(data.get("workplane_x_dir", (1.0, 0.0, 0.0))),
+        _to_3tuple(data.get("workplane_origin", (0.0, 0.0, 0.0))),
+        _to_3tuple(data.get("workplane_normal", (0.0, 0.0, 1.0))),
+        _to_3tuple(data.get("workplane_x_dir", (1.0, 0.0, 0.0))),
    )

    geometry: Optional[OCCGeometryObject] = None
@@ -277,7 +383,7 @@ def _sketch_from_dict(
        geometry = geometry_loader(data["geometry_ref"]) if data.get("has_geometry") else None

    sk = Sketch(
-        id=data.get("id") or None,
+        id=_saved_id(data),
        name=data.get("name", "Untitled Sketch"),
        occ_sketch=occ_sketch,
        geometry=geometry,
@@ -314,7 +420,7 @@ def _component_from_dict(
    sketch_geometry_loader: Optional[Callable[[str], Optional[OCCGeometryObject]]] = None,
 ) -> Component:
    comp = Component(
-        id=data.get("id") or None,
+        id=_saved_id(data),
        name=data.get("name", "Untitled Component"),
        description=data.get("description", ""),
        active_sketch=data.get("active_sketch"),
@@ -335,7 +441,22 @@ def _component_from_dict(
        src_id = body_data.get("source_sketch_id")
        if src_id and src_id in comp.sketches:
            src_sketch = comp.sketches[src_id]
-        comp.bodies[bid] = _body_from_dict(body_data, body_geometry_loader, src_sketch)
+        body = _body_from_dict(body_data, body_geometry_loader, src_sketch)
+        # Parametric feature history (new files).  Old files carry no
+        # "features" key — the body keeps an empty list and is migrated
+        # lazily at update time (see ``_ensure_feature_history``).
+        for f_data in body_data.get("features") or []:
+            body.features.append(_feature_from_dict(f_data, comp.sketches))
+        if body_data.get("features_base_snapshot") and body.features:
+            # The list was saved WITHOUT its leading "base" snapshot;
+            # restore it from the dedicated STEP member.
+            base_geom: Optional[OCCGeometryObject] = None
+            base_ref = body_data.get("base_geometry_ref")
+            if base_ref and body_geometry_loader is not None:
+                base_geom = body_geometry_loader(base_ref)
+            if base_geom is not None:
+                body.features.insert(0, Feature(operation="base", geometry=base_geom))
+        comp.bodies[bid] = body

    return comp

@@ -347,8 +468,8 @@ def _connector_to_dict(conn: Connector) -> Dict[str, Any]:
        "position": list(conn.position),
        "normal": list(conn.normal),
        "x_dir": list(conn.x_dir),
-        "axis_rotation": float(conn.axis_rotation),
-        "offset": float(conn.offset),
+        "axis_rotation": _to_float(conn.axis_rotation, 0.0),
+        "offset": _to_float(conn.offset, 0.0),
        "assembly_component_id": conn.assembly_component_id,
        "source_obj_id": conn.source_obj_id,
        "partner_ac_id": conn.partner_ac_id,
@@ -362,13 +483,13 @@ def _connector_to_dict(conn: Connector) -> Dict[str, Any]:

 def _connector_from_dict(data: Dict[str, Any]) -> Connector:
    conn = Connector(
-        id=data.get("id") or None,
+        id=_saved_id(data),
        name=data.get("name", "Untitled Connector"),
        position=_to_3tuple(data.get("position")),
        normal=_to_3tuple(data.get("normal")),
        x_dir=_to_3tuple(data.get("x_dir")),
-        axis_rotation=float(data.get("axis_rotation", 0.0)),
-        offset=float(data.get("offset", 0.0)),
+        axis_rotation=_to_float(data.get("axis_rotation"), 0.0),
+        offset=_to_float(data.get("offset"), 0.0),
        assembly_component_id=data.get("assembly_component_id", ""),
        source_obj_id=data.get("source_obj_id", ""),
    )
@@ -396,7 +517,7 @@ def _assembly_component_to_dict(ac: AssemblyComponent) -> Dict[str, Any]:

 def _assembly_component_from_dict(data: Dict[str, Any]) -> AssemblyComponent:
    ac = AssemblyComponent(
-        id=data.get("id") or None,
+        id=_saved_id(data),
        component_id=data.get("component_id", ""),
        name=data.get("name", "Untitled Instance"),
        position=_to_3vec(data.get("position")),
@@ -422,7 +543,7 @@ def _assembly_connection_to_dict(c: AssemblyConnection) -> Dict[str, Any]:

 def _assembly_connection_from_dict(data: Dict[str, Any]) -> AssemblyConnection:
    conn = AssemblyConnection(
-        id=data.get("id") or None,
+        id=_saved_id(data),
        first_ac_id=data.get("first_ac_id", ""),
        second_ac_id=data.get("second_ac_id", ""),
        first_connector_id=data.get("first_connector_id"),
@@ -446,7 +567,7 @@ def _assembly_to_dict(asm: Assembly) -> Dict[str, Any]:

 def _assembly_from_dict(data: Dict[str, Any]) -> Assembly:
    asm = Assembly(
-        id=data.get("id") or None,
+        id=_saved_id(data),
        name=data.get("name", "Untitled Assembly"),
        active_assembly_component=data.get("active_assembly_component"),
    )
@@ -454,7 +575,7 @@ def _assembly_from_dict(data: Dict[str, Any]) -> Assembly:
    asm.modified_at = _parse_iso(data.get("modified_at"))
    for cid, ac_data in (data.get("components") or {}).items():
        asm.components[cid] = _assembly_component_from_dict(ac_data)
-    for c_data in (data.get("connections") or []):
+    for c_data in data.get("connections") or []:
        asm.connections.append(_assembly_connection_from_dict(c_data))
    return asm

@@ -517,7 +638,9 @@ def _read_step_bytes(
        with open(tmp_path, "wb") as f:
            f.write(data)
        geom = kernel.import_step(tmp_path)
-        return geom
+        from typing import cast
+
+        return cast(OCCGeometryObject, geom)
    except Exception as exc:
        logger.warning("Failed to read STEP: %s", exc)
        return None
@@ -580,6 +703,20 @@ def save_project(
            arcname = f"bodies/{body_id}.step"
            body_files.append((arcname, step_bytes))
            manifest["components"][comp_id]["bodies"][body_id]["geometry_ref"] = arcname
+            # Base-snapshot STEP for migrated legacy bodies whose feature
+            # list starts with a frozen "base" geometry snapshot.
+            if (
+                body.features
+                and body.features[0].operation == "base"
+                and body.features[0].geometry is not None
+            ):
+                base_bytes = _write_step_for_body(kernel, body.features[0].geometry)
+                if base_bytes is not None:
+                    base_arcname = f"bodies/{body_id}_base.step"
+                    body_files.append((base_arcname, base_bytes))
+                    manifest["components"][comp_id]["bodies"][body_id]["base_geometry_ref"] = (
+                        base_arcname
+                    )

    # Per-sketch STEP files (solved face geometry).
    sketch_files: List[Tuple[str, bytes]] = []
@@ -672,7 +809,10 @@ def load_project(filepath: str) -> Tuple[Project, Dict[str, Any]]:

    with zipfile.ZipFile(filepath, "r") as zipf:
        manifest_raw = zipf.read("project.json")
-        manifest = json.loads(manifest_raw.decode("utf-8"))
+        try:
+            manifest = json.loads(manifest_raw.decode("utf-8"))
+        except (ValueError, UnicodeDecodeError) as exc:
+            raise RuntimeError(f"Corrupt project file (bad JSON): {filepath}") from exc
        view_state: Dict[str, Any] = manifest.get("view_state") or {}

        # If a sketch's occ_sketch is referenced as a separate file, read
@@ -687,12 +827,21 @@ def load_project(filepath: str) -> Tuple[Project, Dict[str, Any]]:
                except KeyError:
                    logger.warning("Sketch meta missing in archive: %s", ref)
                    continue
-                meta = json.loads(meta_bytes.decode("utf-8"))
+                try:
+                    meta = json.loads(meta_bytes.decode("utf-8"))
+                except (ValueError, UnicodeDecodeError) as exc:
+                    logger.warning("Sketch meta corrupt in archive: %s (%s)", ref, exc)
+                    continue
                sk_data["occ_sketch"] = meta.get("occ_sketch")
                # Workplane fields on the sketch-level file override the
                # embedded ones (source of truth lives in the sidecar).
-                for k in ("workplane_origin", "workplane_normal", "workplane_x_dir",
-                          "is_solved", "is_fully_constrained"):
+                for k in (
+                    "workplane_origin",
+                    "workplane_normal",
+                    "workplane_x_dir",
+                    "is_solved",
+                    "is_fully_constrained",
+                ):
                    if k in meta:
                        sk_data[k] = meta[k]

@@ -24,6 +24,7 @@ from fluency.ui.dialogs import (
    ExtrudeDialog,
    OffsetDialog,
    RevolveDialog,
+    ThreadDialog,
    WorkplaneOrientationDialog,
 )
 from fluency.ui.main_window import MainWindow
@@ -37,6 +38,7 @@ __all__ = [
    "ExtrudeDialog",
    "RevolveDialog",
    "OffsetDialog",
+    "ThreadDialog",
    "WorkplaneOrientationDialog",
    "main",
 ]
@@ -60,9 +60,9 @@ class Workplane:
        x = x / x_norm
        y = np.cross(n, x)
        y = y / np.linalg.norm(y)
-        self.normal = tuple(float(v) for v in n)
-        self.x_dir = tuple(float(v) for v in x)
-        self._y_dir = tuple(float(v) for v in y)
+        self.normal = (float(n[0]), float(n[1]), float(n[2]))
+        self.x_dir = (float(x[0]), float(x[1]), float(x[2]))
+        self._y_dir = (float(y[0]), float(y[1]), float(y[2]))

    @property
    def y_dir(self) -> Tuple[float, float, float]:
@@ -206,6 +206,84 @@ class Sketch:
        self.modified_at = datetime.now()


+@dataclass
+class Feature:
+    """
+    One operation in a body's parametric feature history.
+
+    Bodies rebuild their geometry by replaying their ordered feature
+    list from scratch (see ``Body.features``).  This is what makes
+    sketch edits propagate: a moved circle re-cuts at the new position
+    on a freshly rebuilt base instead of adding to the previous result.
+
+    ``operation`` is one of:
+      - "extrude": base solid, ``kernel.extrude`` of the sketch profile
+      - "revolve": base solid, ``kernel.revolve`` of the sketch profile
+      - "cut":    boolean difference of the running geometry with the
+                  extruded sketch profile
+      - "union":  boolean union of the running geometry with the
+                  extruded sketch profile
+      - "fillet": round a set of edges of the running geometry
+                  (``radius``, ``tangent_propagation``, ``scope``,
+                  ``edge_refs`` — see below)
+      - "chamfer": bevel a set of edges of the running geometry
+                  (same fields as "fillet"; ``radius`` holds the
+                  chamfer size)
+      - "array" / "pattern": repeat the running solid in a linear or
+                  circular array.  ``pattern_type`` is "linear" or
+                  "circular"; ``count`` is the total number of items
+                  (original + copies).  Linear uses ``direction``
+                  (unit vector) and ``spacing`` (mm between adjacent
+                  items); circular reuses ``axis`` + ``origin`` for the
+                  rotation axis and ``angle`` for the total angular
+                  span in degrees (copies evenly distributed).
+      - "base":   frozen geometry snapshot (``geometry`` field) — used
+                  to migrate legacy bodies whose original base feature
+                  is unknown.  Never the result of a user operation.
+    """
+
+    id: str = field(default_factory=lambda: str(uuid.uuid4()))
+    operation: str = "extrude"
+
+    sketch: Optional[Sketch] = None  # runtime ref; serialized as sketch_id
+    length: Optional[float] = None
+    symmetric: bool = False
+    invert: bool = False
+    through_all: bool = False
+    cut_all_bodies: bool = False
+    face_index: Optional[int] = None  # which sketch face was selected
+    angle: float = 360.0  # revolve only (degrees)
+    axis: Tuple[float, float, float] = (0, 0, 1)  # revolve only: unit axis vector
+    origin: Tuple[float, float, float] = (0.0, 0.0, 0.0)  # revolve only: axis point
+    axis_line_id: Optional[int] = None  # revolve only: sketch line entity used as axis
+
+    # "base" features only: frozen pre-feature geometry snapshot.
+    geometry: Optional[OCCGeometryObject] = None
+
+    # "fillet" / "chamfer" features only: radius (mm) of the round or the
+    # chamfer size, whether the op should extend along edges tangent to the
+    # picked ones, the edge scope ("selected" = edges between the two
+    # picked faces, "all" = every edge of the body), and stable
+    # fingerprints of the selected edges so the replay can re-find them
+    # after the base geometry is rebuilt.
+    radius: Optional[float] = None
+    tangent_propagation: bool = False
+    scope: str = "selected"
+    edge_refs: List[str] = field(default_factory=list)
+
+    # "array" / "pattern" features only: repeat the running solid.
+    # ``pattern_type`` is "linear" or "circular"; ``count`` is the total
+    # number of items including the original.  Linear arrays use
+    # ``direction`` (unit vector) and ``spacing`` (mm); circular arrays
+    # reuse ``axis`` / ``origin`` / ``angle`` (total angular span, deg).
+    pattern_type: str = "linear"
+    count: int = 2
+    spacing: float = 10.0
+    direction: Tuple[float, float, float] = (1.0, 0.0, 0.0)
+
+    created_at: datetime = field(default_factory=datetime.now)
+
+
@dataclass
 class Body:
    """
@@ -222,6 +300,12 @@ class Body:
    source_sketch: Optional[Sketch] = None
    source_operation: str = "extrude"

+    # Parametric feature history.  When non-empty, the body is rebuilt
+    # from scratch by replaying these features in order; the flat
+    # extrude_* / source_* fields below then only mirror the LAST
+    # feature for backward compatibility (old files, old code paths).
+    features: List[Feature] = field(default_factory=list)
+
    # Re-extrusion parameters — stored so the body can be rebuilt from
    # its source sketch when the sketch is edited.  None means the body
    # was not created by an extrude-type operation and cannot be auto-
@@ -232,6 +316,7 @@ class Body:
    extrude_cut: bool = False
    extrude_union: bool = False
    extrude_through_all: bool = False
+    extrude_cut_all_bodies: bool = False  # cut through all bodies in component
    extrude_face_index: Optional[int] = None  # which sketch face was selected
    extrude_target_body_id: Optional[str] = None  # for cut/union: target body id
    needs_update: bool = False  # True when source sketch changed since last extrude
@@ -13,16 +13,58 @@ import unittest
 # Allow running this file directly: ``python tests/test_project_io.py``.
 sys.path.insert(0, os.path.join(os.path.dirname(__file__), os.pardir, "src"))

-from fluency.io.project_io import save_project, load_project
+from fluency.io.project_io import save_project, load_project, _feature_to_dict, _feature_from_dict
 from fluency.models.data_model import (
    Project,
    Component,
    Body,
+    Sketch,
    Workplane,
    Assembly,
+    Feature,
 )


+class TestRevolveAxisSerialization(unittest.TestCase):
+    """Revolve features persist their revolve axis across save/load."""
+
+    def test_axis_round_trip(self):
+        sk = Sketch()
+        feat = Feature(
+            operation="revolve",
+            angle=180.0,
+            axis=(1, 0, 0),
+            origin=(10.0, 5.0, 0.0),
+            axis_line_id=7,
+        )
+        feat.sketch = sk
+        data = _feature_to_dict(feat)
+        self.assertEqual(data["axis"], [1.0, 0.0, 0.0])
+        self.assertEqual(data["origin"], [10.0, 5.0, 0.0])
+        self.assertEqual(data["axis_line_id"], 7)
+        restored = _feature_from_dict(data, {sk.id: sk})
+        self.assertEqual(tuple(restored.axis), (1.0, 0.0, 0.0))
+        self.assertEqual(tuple(restored.origin), (10.0, 5.0, 0.0))
+        self.assertEqual(restored.axis_line_id, 7)
+        self.assertEqual(restored.angle, 180.0)
+
+    def test_default_axis(self):
+        """Old files without axis fields fall back to Z axis at the origin."""
+        sk = Sketch()
+        data = _feature_to_dict(Feature(operation="revolve", angle=90.0))
+        restored = _feature_from_dict(data, {sk.id: sk})
+        self.assertEqual(tuple(restored.axis), (0, 0, 1))
+        self.assertEqual(tuple(restored.origin), (0.0, 0.0, 0.0))
+        self.assertIsNone(restored.axis_line_id)
+        # legacy file without the keys
+        del data["axis"]
+        del data["origin"]
+        del data["axis_line_id"]
+        restored = _feature_from_dict(data, {sk.id: sk})
+        self.assertEqual(tuple(restored.axis), (0, 0, 1))
+        self.assertEqual(tuple(restored.origin), (0.0, 0.0, 0.0))
+
+
 class TestProjectIO(unittest.TestCase):
    """Round-trip the same project through save/load and check equivalence."""

@@ -892,7 +892,7 @@ class Ui_fluencyCAD(object):
        self.groupBox.setTitle(QCoreApplication.translate("fluencyCAD", u"Modify", None))
        self.pb_revop.setText(QCoreApplication.translate("fluencyCAD", u"Rev", None))
        self.pb_extrdop.setText(QCoreApplication.translate("fluencyCAD", u"Extrd", None))
-        self.pb_arrayop.setText(QCoreApplication.translate("fluencyCAD", u"Arry", None))
+        self.pb_arrayop.setText(QCoreApplication.translate("fluencyCAD", u"Array", None))
        self.pb_cutop.setText(QCoreApplication.translate("fluencyCAD", u"Cut", None))
        self.pb_combop.setText(QCoreApplication.translate("fluencyCAD", u"Comb", None))
        self.pb_moveop.setText(QCoreApplication.translate("fluencyCAD", u"Mve", None))
@@ -20,6 +20,24 @@ class Viewer3DWidget(QWidget):
    # Emitted when face-pick mode is cancelled (Esc) so the host can uncheck.
    pickFaceCancelled = Signal()

+    # Emitted when the user picks a face for the fillet tool (ANY face,
+    # planar or curved).  Payload: the raw TopoDS_Face.  The owning body is
+    # read from ``_last_pick_owner_obj_id`` (same stash as facePicked).
+    filletFacePicked = Signal(object)
+    # Emitted when fillet pick mode is cancelled (Esc).
+    filletPickCancelled = Signal()
+
+    # Emitted when the user picks a face for the chamfer tool (ANY face,
+    # planar or curved).  Payload: the raw TopoDS_Face.
+    chamferFacePicked = Signal(object)
+    # Emitted when chamfer pick mode is cancelled (Esc).
+    chamferPickCancelled = Signal()
+
+    # Emitted when the user picks a cylindrical face for the thread tool.
+    threadFacePicked = Signal(object)
+    # Emitted when thread pick mode is cancelled (Esc).
+    threadPickCancelled = Signal()
+
    # Emitted when the user picks an entity for a connector point (assembly).
    # Payload: (origin, normal, x_dir, entity_type, face_or_edge_or_vertex, owner_obj_id).
    connectorPicked = Signal(tuple, tuple, tuple, str, object, str)
@@ -41,14 +59,30 @@ class Viewer3DWidget(QWidget):
    # Payload: (eye, at, up) — each is a tuple of 3 floats.
    cameraChanged = Signal(tuple, tuple, tuple)

+    # Emitted when the user clicks a part of the world-space sketch gizmo
+    # (the triad at the sketch midpoint).  Payload:
+    #   kind      — "center" | "axis_x" | "axis_y" | "axis_z" |
+    #               "plane_xy" | "plane_yz" | "plane_xz"
+    #   position  — picked world point (triad origin for axes/center,
+    #               plane quad centre for planes)
+    #   direction — axis unit vector / plane normal / (0,0,0) for center
+    #   normal    — sketch workplane normal
+    #   x_dir     — sketch workplane x direction
+    sketchGizmoPicked = Signal(str, tuple, tuple, tuple, tuple)
+    # Hover feedback: part kind string under the cursor, or None when the
+    # cursor left the gizmo.
+    sketchGizmoHover = Signal(object)
+    # Emitted when gizmo pick mode is cancelled (Esc) so the host can reset.
+    sketchGizmoCancelled = Signal()
+
    def __init__(self, parent=None):
        super().__init__(parent)
        # For OCC's direct OpenGL rendering we need Qt to not paint over it.
-        self.setAttribute(Qt.WA_PaintOnScreen)
-        self.setAttribute(Qt.WA_OpaquePaintEvent)
+        self.setAttribute(Qt.WidgetAttribute.WA_PaintOnScreen)
+        self.setAttribute(Qt.WidgetAttribute.WA_OpaquePaintEvent)
        self.setAutoFillBackground(False)
        # Accept keyboard focus so navigation shortcuts (F, R, 1-7, P, O) work.
-        self.setFocusPolicy(Qt.StrongFocus)
+        self.setFocusPolicy(Qt.FocusPolicy.StrongFocus)
        # Enable mouse tracking so ``mouseMoveEvent`` fires even without a
        # button held — required for the connector-pick hover gizmo (and any
        # status-bar hover feedback) to show under the cursor as the user
@@ -64,6 +98,12 @@ class Viewer3DWidget(QWidget):
        # When True, a left-click picks a planar face (for sketch-on-surface)
        # instead of orbiting the camera.  Set via set_pick_face_mode().
        self._pick_face_mode: bool = False
+        # When True, a left-click picks ANY face for the fillet tool.
+        self._fillet_pick_mode: bool = False
+        # When True, a left-click picks ANY face for the chamfer tool.
+        self._chamfer_pick_mode: bool = False
+        # When True, a left-click picks a cylindrical face for the thread tool.
+        self._thread_pick_mode: bool = False
        # When True, a left-click picks an entity for a connector point
        # (assembly component connection).
        self._connector_pick_mode: bool = False
@@ -87,6 +127,16 @@ class Viewer3DWidget(QWidget):
        # target a cut/union extrude against the body the sketch was
        # projected onto).
        self._last_pick_owner_obj_id: Optional[str] = None
+        # World-space sketch reference gizmo (triad at the sketch midpoint).
+        # ``_sketch_gizmo_frame`` is (origin, normal, x_dir) of the gizmo;
+        # None while no triad is shown.
+        self._sketch_gizmo_frame: Optional[Tuple[tuple, tuple, tuple]] = None
+        # When True, a left-click picks gizmo parts only (no orbit); Esc
+        # cancels.  Otherwise the gizmo is pickable implicitly during normal
+        # navigation (Fusion-style) whenever it is shown.
+        self._sketch_gizmo_pick_mode: bool = False
+        # Currently hovered gizmo part kind (for highlight bookkeeping).
+        self._sketch_gizmo_hover_kind: Optional[str] = None

    def _init_renderer(self) -> None:
        """Create the best available renderer."""
@@ -275,6 +325,35 @@ class Viewer3DWidget(QWidget):
        self._renderer.fit_camera()
        self._renderer.render()

+    def fit_camera_to_box(self, bnd_box: Any, padding: float = 0.05) -> None:
+        """Fit the camera to a specific 3D bounding box (``Bnd_Box``).
+
+        Used by the array tool so the dialog preview frames exactly the
+        space the pattern copies occupy.  Falls back to fitting the whole
+        scene on renderers without box fitting (e.g. the Pygfx fallback).
+        """
+        self._ensure_initialized()
+        fn = getattr(self._renderer, "fit_camera_to_box", None)
+        if fn is not None:
+            fn(bnd_box, padding)
+            self._renderer.render()
+            return
+        self.fit_camera()
+
+    def box_fully_visible(self, bnd_box: Any, margin: float = 0.05) -> bool:
+        """True when the box's 8 corners all project inside the viewport.
+
+        The array preview uses this to decide when a grown pattern has
+        moved copies off-screen and the camera needs re-fitting.  On
+        renderers without the check (Pygfx fallback) it returns True so
+        no re-fit is forced.
+        """
+        self._ensure_initialized()
+        fn = getattr(self._renderer, "box_fully_visible", None)
+        if fn is not None:
+            return bool(fn(bnd_box, margin))
+        return True
+
    # ─── Workplane visualization ───────────────────────────────────────────

    def show_workplane(
@@ -312,17 +391,43 @@ class Viewer3DWidget(QWidget):
    def mousePressEvent(self, event):
        self._ensure_initialized()
        # Face-pick mode: a left-click selects a planar face to sketch on.
-        if self._pick_face_mode and event.button() == Qt.LeftButton:
+        if self._pick_face_mode and event.button() == Qt.MouseButton.LeftButton:
            self._handle_face_pick(event)
            return
+        # Fillet pick mode: a left-click selects any face (planar or curved).
+        if self._fillet_pick_mode and event.button() == Qt.MouseButton.LeftButton:
+            self._handle_fillet_face_pick(event)
+            return
+        # Chamfer pick mode: a left-click selects any face (planar or curved).
+        if self._chamfer_pick_mode and event.button() == Qt.MouseButton.LeftButton:
+            self._handle_chamfer_face_pick(event)
+            return
+        # Thread pick mode: a left-click selects a cylindrical face.
+        if self._thread_pick_mode and event.button() == Qt.MouseButton.LeftButton:
+            self._handle_thread_face_pick(event)
+            return
        # Connector pick mode: a left-click selects a face for a connection point.
-        if self._connector_pick_mode and event.button() == Qt.LeftButton:
+        if self._connector_pick_mode and event.button() == Qt.MouseButton.LeftButton:
            self._handle_connector_pick(event)
            return
        # Assembly move mode: start dragging the clicked body.
-        if self._assembly_move_mode and event.button() == Qt.LeftButton:
+        if self._assembly_move_mode and event.button() == Qt.MouseButton.LeftButton:
            self._handle_assembly_move_press(event)
            return
+        # World sketch gizmo: a click on a part selects it (Fusion-style),
+        # even during normal navigation.  In explicit gizmo-pick mode an
+        # off-gizmo click does nothing (no orbit); otherwise it falls
+        # through to orbit/pan below.
+        if event.button() == Qt.MouseButton.LeftButton and self._sketch_gizmo_enabled():
+            fn = getattr(self._renderer, "pick_sketch_gizmo", None)
+            if fn is not None:
+                pos = event.position().toPoint() if hasattr(event, "position") else event.pos()
+                kind = fn(pos.x(), pos.y())
+                if kind is not None:
+                    self._handle_sketch_gizmo_pick(event, kind)
+                    return
+            if self._sketch_gizmo_pick_mode:
+                return  # explicit mode: off-gizmo clicks do not orbit
        self._renderer.handle_mouse_press(event)
        super().mousePressEvent(event)

@@ -346,15 +451,39 @@ class Viewer3DWidget(QWidget):
                self._renderer.handle_mouse_move(event)
            super().mouseMoveEvent(event)
            return
+        # In fillet pick mode, keep dynamic highlighting too.
+        if self._fillet_pick_mode:
+            if hasattr(self._renderer, "handle_mouse_move"):
+                self._renderer.handle_mouse_move(event)
+            super().mouseMoveEvent(event)
+            return
+        # In chamfer pick mode, keep dynamic highlighting too.
+        if self._chamfer_pick_mode:
+            if hasattr(self._renderer, "handle_mouse_move"):
+                self._renderer.handle_mouse_move(event)
+            super().mouseMoveEvent(event)
+            return
+        # In thread pick mode, keep dynamic highlighting.
+        if self._thread_pick_mode:
+            if hasattr(self._renderer, "handle_mouse_move"):
+                self._renderer.handle_mouse_move(event)
+            super().mouseMoveEvent(event)
+            return
        # Active drag in assembly move mode.
        if self._move_drag_active:
            self._handle_assembly_move_move(event)
            super().mouseMoveEvent(event)
            return
+        # World sketch gizmo hover: highlight the part under the cursor.
+        if self._sketch_gizmo_enabled():
+            self._handle_sketch_gizmo_hover(event)
+            if self._sketch_gizmo_pick_mode:
+                super().mouseMoveEvent(event)
+                return
        self._renderer.handle_mouse_move(event)
        super().mouseMoveEvent(event)

-    def paintEngine(self):
+    def paintEngine(self) -> Any:
        """Return None to prevent Qt from painting over OCC's direct OpenGL."""
        return None

@@ -437,6 +566,127 @@ class Viewer3DWidget(QWidget):
            return self._renderer.get_camera_fov()
        return 45.0

+    # ─── World sketch reference gizmo (triad at the sketch midpoint) ────────
+
+    def show_sketch_gizmo(
+        self,
+        origin: Tuple[float, float, float],
+        normal: Tuple[float, float, float],
+        x_dir: Tuple[float, float, float],
+        size: float = 40.0,
+    ) -> None:
+        """Show the selectable X/Y/Z triad in the 3D world at *origin*.
+
+        *origin* should be the midpoint of the active sketch's geometry and
+        the triad is aligned to the sketch's workplane frame.  Call again
+        with a new origin to keep it in sync as the sketch is edited.
+        No-op on renderers without gizmo support (Pygfx fallback).
+        """
+        self._ensure_initialized()
+        fn = getattr(self._renderer, "show_sketch_gizmo", None)
+        if fn is None:
+            return
+        fn(origin, normal, x_dir, size)
+        self._sketch_gizmo_frame = (tuple(origin), tuple(normal), tuple(x_dir))
+        self._sketch_gizmo_hover_kind = None
+        self._renderer.render()
+
+    def remove_sketch_gizmo(self) -> None:
+        """Hide the world sketch triad, if any."""
+        if self._initialized and self._renderer is not None:
+            fn = getattr(self._renderer, "remove_sketch_gizmo", None)
+            if fn is not None:
+                fn()
+                self._renderer.render()
+        self._sketch_gizmo_frame = None
+        self._sketch_gizmo_hover_kind = None
+
+    def set_sketch_gizmo_pick_mode(self, enabled: bool) -> None:
+        """Toggle explicit gizmo-pick mode.
+
+        When enabled, left-clicks select gizmo parts only (the camera does
+        not orbit) and Esc exits the mode.  When disabled, the gizmo is
+        still pickable implicitly during normal navigation (Fusion-style)
+        whenever it is shown.  Mutually exclusive with the other pick modes.
+        """
+        self._sketch_gizmo_pick_mode = bool(enabled)
+        if enabled:
+            self._pick_face_mode = False
+            self._fillet_pick_mode = False
+            self._chamfer_pick_mode = False
+            self._thread_pick_mode = False
+            self._connector_pick_mode = False
+            self._assembly_move_mode = False
+            self._move_drag_active = False
+            self.setCursor(Qt.CursorShape.CrossCursor)
+            self.setFocus()
+        elif not (
+            self._pick_face_mode
+            or self._fillet_pick_mode
+            or self._chamfer_pick_mode
+            or self._thread_pick_mode
+            or self._connector_pick_mode
+        ):
+            self.unsetCursor()
+
+    def is_sketch_gizmo_pick_mode(self) -> bool:
+        return self._sketch_gizmo_pick_mode
+
+    def get_sketch_gizmo_frame(self) -> Optional[Tuple[tuple, tuple, tuple]]:
+        """Return the (origin, normal, x_dir) of the shown triad, or None."""
+        return self._sketch_gizmo_frame
+
+    def _sketch_gizmo_enabled(self) -> bool:
+        """True when the triad is shown AND no other mode owns the pointer."""
+        if self._sketch_gizmo_frame is None:
+            return False
+        if self._sketch_gizmo_pick_mode:
+            return True
+        if self._assembly_move_mode or self._move_drag_active:
+            return False
+        return not (
+            self._pick_face_mode
+            or self._fillet_pick_mode
+            or self._chamfer_pick_mode
+            or self._thread_pick_mode
+            or self._connector_pick_mode
+        )
+
+    def _handle_sketch_gizmo_hover(self, event) -> None:
+        """Highlight the gizmo part under the cursor and emit hover signal."""
+        fn = getattr(self._renderer, "pick_sketch_gizmo", None)
+        if fn is None:
+            return
+        pos = event.position().toPoint() if hasattr(event, "position") else event.pos()
+        kind = fn(pos.x(), pos.y())
+        if kind == self._sketch_gizmo_hover_kind:
+            return
+        self._sketch_gizmo_hover_kind = kind
+        if kind is not None:
+            hl = getattr(self._renderer, "highlight_sketch_gizmo_part", None)
+            if hl is not None:
+                hl(kind)
+        else:
+            cl = getattr(self._renderer, "clear_sketch_gizmo_highlight", None)
+            if cl is not None:
+                cl()
+        self.sketchGizmoHover.emit(kind)
+
+    def _handle_sketch_gizmo_pick(self, event, kind: str) -> None:
+        """Emit sketchGizmoPicked for the clicked part with world metadata."""
+        frame = self._sketch_gizmo_frame
+        normal = tuple(frame[1]) if frame else (0.0, 0.0, 1.0)
+        x_dir = tuple(frame[2]) if frame else (1.0, 0.0, 0.0)
+        position = tuple(frame[0]) if frame else (0.0, 0.0, 0.0)
+        direction = (0.0, 0.0, 0.0)
+        info_fn = getattr(self._renderer, "sketch_gizmo_pick_info", None)
+        if info_fn is not None:
+            info = info_fn(kind)
+            if info:
+                position = tuple(info["position"])
+                direction = tuple(info["direction"])
+        self.sketchGizmoPicked.emit(kind, position, direction, normal, x_dir)
+
    # ─── Face-pick mode (sketch-on-surface) ────────────────────────────────

    def set_pick_face_mode(self, enabled: bool) -> None:
@@ -447,13 +697,155 @@ class Viewer3DWidget(QWidget):
        """
        self._pick_face_mode = bool(enabled)
        if enabled:
-            self.setCursor(Qt.CrossCursor)
+            self._sketch_gizmo_pick_mode = False
+            self.setCursor(Qt.CursorShape.CrossCursor)
        else:
            self.unsetCursor()

    def is_pick_face_mode(self) -> bool:
        return self._pick_face_mode

+    # ─── Fillet pick mode (any-face picking) ────────────────────────────────
+
+    def set_fillet_pick_mode(self, enabled: bool) -> None:
+        """Toggle fillet face-pick mode (any face — planar or curved).
+
+        The cursor selects faces for the fillet tool instead of orbiting the
+        camera.  Mutually exclusive with the other pick modes: entering this
+        mode switches the others off.
+        """
+        self._fillet_pick_mode = bool(enabled)
+        if enabled:
+            self._sketch_gizmo_pick_mode = False
+            # Pick modes are mutually exclusive — entering fillet mode
+            # disables chamfer / sketch-on-surface / connector / assembly modes.
+            self._chamfer_pick_mode = False
+            self._pick_face_mode = False
+            self._connector_pick_mode = False
+            self._assembly_move_mode = False
+            self._move_drag_active = False
+            self.setCursor(Qt.CursorShape.CrossCursor)
+        elif not self._pick_face_mode and not self._chamfer_pick_mode and not self._connector_pick_mode:
+            self.unsetCursor()
+
+    def is_fillet_pick_mode(self) -> bool:
+        return self._fillet_pick_mode
+
+    # ─── Chamfer pick mode (any-face picking) ──────────────────────────────
+
+    def set_chamfer_pick_mode(self, enabled: bool) -> None:
+        """Toggle chamfer face-pick mode (any face — planar or curved).
+
+        The cursor selects faces for the chamfer tool instead of orbiting
+        the camera.  Mutually exclusive with the other pick modes.
+        """
+        self._chamfer_pick_mode = bool(enabled)
+        if enabled:
+            self._sketch_gizmo_pick_mode = False
+            self._fillet_pick_mode = False
+            self._pick_face_mode = False
+            self._connector_pick_mode = False
+            self._assembly_move_mode = False
+            self._move_drag_active = False
+            self.setCursor(Qt.CursorShape.CrossCursor)
+        elif not self._pick_face_mode and not self._fillet_pick_mode and not self._connector_pick_mode:
+            self.unsetCursor()
+
+    def is_chamfer_pick_mode(self) -> bool:
+        return self._chamfer_pick_mode
+
+    def _handle_chamfer_face_pick(self, event: Any) -> None:
+        """Detect any face under the click and emit chamferFacePicked."""
+        self._ensure_initialized()
+        picker = getattr(self._renderer, "pick_face", None)
+        if picker is None:
+            logger.warning("Renderer has no pick_face support")
+            return
+        pos = event.position().toPoint() if hasattr(event, "position") else event.pos()
+        info = picker(pos.x(), pos.y())
+        if info is None:
+            logger.info("Chamfer face pick: no face under cursor")
+            return
+        self._last_pick_owner_obj_id = info.get("owner_obj_id")
+        self.chamferFacePicked.emit(info["face"])
+
+    def highlight_faces(self, faces: List[Any]) -> None:
+        """Tint all faces in *faces* so both fillet picks stay visible."""
+        self._ensure_initialized()
+        fn = getattr(self._renderer, "highlight_faces", None)
+        if fn is not None:
+            fn(faces)
+            self._renderer.render()
+            return
+        # Fallback: single-face highlight for the last picked face.
+        if faces:
+            self.highlight_face(faces[-1])
+
+    def clear_faces_highlight(self) -> None:
+        """Remove the multi-face fillet-pick overlays, if any."""
+        if not self._initialized or self._renderer is None:
+            return
+        fn = getattr(self._renderer, "clear_faces_highlight", None)
+        if fn is not None:
+            fn()
+            self._renderer.render()
+
+    def _handle_fillet_face_pick(self, event: Any) -> None:
+        """Detect any face under the click and emit filletFacePicked."""
+        self._ensure_initialized()
+        picker = getattr(self._renderer, "pick_face", None)
+        if picker is None:
+            logger.warning("Renderer has no pick_face support")
+            return
+        pos = event.position().toPoint() if hasattr(event, "position") else event.pos()
+        info = picker(pos.x(), pos.y())
+        if info is None:
+            logger.info("Fillet face pick: no face under cursor")
+            return
+        # Stash the owner so MainWindow can pair the face with its body
+        # (same convention as sketch-on-face picking).
+        self._last_pick_owner_obj_id = info.get("owner_obj_id")
+        self.filletFacePicked.emit(info["face"])
+
+    # ─── Thread pick mode ─────────────────────────────────────────────────
+
+    def set_thread_pick_mode(self, enabled: bool) -> None:
+        """Toggle thread face-pick mode (cylindrical face only).
+
+        When enabled, a left-click picks a cylindrical face for the thread
+        tool.  Mutually exclusive with other pick modes.
+        """
+        self._thread_pick_mode = bool(enabled)
+        if enabled:
+            self._sketch_gizmo_pick_mode = False
+            self._pick_face_mode = False
+            self._fillet_pick_mode = False
+            self._chamfer_pick_mode = False
+            self._connector_pick_mode = False
+            self._assembly_move_mode = False
+            self._move_drag_active = False
+            self.setCursor(Qt.CursorShape.CrossCursor)
+        elif not self._pick_face_mode and not self._fillet_pick_mode and not self._chamfer_pick_mode and not self._connector_pick_mode:
+            self.unsetCursor()
+
+    def is_thread_pick_mode(self) -> bool:
+        return self._thread_pick_mode
+
+    def _handle_thread_face_pick(self, event: Any) -> None:
+        """Detect any face under the click and emit threadFacePicked."""
+        self._ensure_initialized()
+        picker = getattr(self._renderer, "pick_face", None)
+        if picker is None:
+            logger.warning("Renderer has no pick_face support")
+            return
+        pos = event.position().toPoint() if hasattr(event, "position") else event.pos()
+        info = picker(pos.x(), pos.y())
+        if info is None:
+            logger.info("Thread face pick: no face under cursor")
+            return
+        self._last_pick_owner_obj_id = info.get("owner_obj_id")
+        self.threadFacePicked.emit(info["face"])
+
    def highlight_face(self, face: Any) -> None:
        """Tint the picked face light-blue/transparent in the 3D viewer."""
        self._ensure_initialized()
@@ -489,7 +881,8 @@ class Viewer3DWidget(QWidget):
        """
        self._connector_pick_mode = bool(enabled)
        if enabled:
-            self.setCursor(Qt.CrossCursor)
+            self._sketch_gizmo_pick_mode = False
+            self.setCursor(Qt.CursorShape.CrossCursor)
            # Disable standard OCC selection so gizmo visuals are not
            # interfered with by dynamic face highlighting.
            fn = getattr(self._renderer, "deactivate_selection_modes", None)
@@ -714,7 +1107,8 @@ class Viewer3DWidget(QWidget):
        """
        self._assembly_move_mode = bool(enabled)
        if enabled:
-            self.setCursor(Qt.SizeAllCursor)
+            self._sketch_gizmo_pick_mode = False
+            self.setCursor(Qt.CursorShape.SizeAllCursor)
        elif not self._pick_face_mode and not self._connector_pick_mode:
            self.unsetCursor()
        if not enabled:
@@ -788,20 +1182,29 @@ class Viewer3DWidget(QWidget):

        # Compute world-space delta.
        modifiers = event.modifiers()
-        if modifiers & Qt.ShiftModifier:
+        if modifiers & Qt.KeyboardModifier.ShiftModifier:
            # Shift+drag: move along camera direction (Z-depth).
            dz_world = dx * world_per_pixel
            dx_world = 0.0
            dy_world = 0.0
        else:
            # Normal drag: move in view plane.
-            dx_world = float(cam_right[0] * dx * world_per_pixel + cam_up[0] * dy * world_per_pixel)
-            dy_world = float(cam_right[1] * dx * world_per_pixel + cam_up[1] * dy * world_per_pixel)
-            dz_world = float(cam_right[2] * dx * world_per_pixel + cam_up[2] * dy * world_per_pixel)
+            try:
+                dx_world = float(
+                    cam_right[0] * dx * world_per_pixel + cam_up[0] * dy * world_per_pixel
+                )
+                dy_world = float(
+                    cam_right[1] * dx * world_per_pixel + cam_up[1] * dy * world_per_pixel
+                )
+                dz_world = float(
+                    cam_right[2] * dx * world_per_pixel + cam_up[2] * dy * world_per_pixel
+                )
+            except (TypeError, ValueError):
+                dx_world = dy_world = dz_world = 0.0

        self.assemblyComponentDragged.emit(self._move_owner_obj_id, dx_world, dy_world, dz_world)

-    def _handle_assembly_move_release(self, event) -> None:
+    def _handle_assembly_move_release(self, event: Any) -> None:
        """Finish the drag, emit final position."""
        self.assemblyMoveFinished.emit(self._move_owner_obj_id)
        self._move_drag_active = False
@@ -811,7 +1214,7 @@ class Viewer3DWidget(QWidget):
        self._move_plane_normal = None
        self._move_initial_position = None

-    def _handle_face_pick(self, event) -> None:
+    def _handle_face_pick(self, event: Any) -> None:
        """Detect a planar face under the click and emit facePicked."""
        self._ensure_initialized()
        picker = getattr(self._renderer, "pick_planar_face", None)
@@ -834,7 +1237,7 @@ class Viewer3DWidget(QWidget):
            info["face"],
        )

-    def set_view(self, view: str):
+    def set_view(self, view: str) -> None:
        # Prefer the renderer's native orientation snap (preserves target,
        # refits the scene).  Falls back to absolute eye positions for
        # renderers that don't implement set_view_orientation.
@@ -856,28 +1259,48 @@ class Viewer3DWidget(QWidget):
            pos, target = positions[view]
            self.set_camera_position(pos, target)

-    def mouseDoubleClickEvent(self, event):
+    def mouseDoubleClickEvent(self, event: Any) -> None:
        # Double-click → fit all (common CAD convention).
        self._ensure_initialized()
-        if event.button() == Qt.LeftButton:
+        if event.button() == Qt.MouseButton.LeftButton:
            self.fit_camera()
        super().mouseDoubleClickEvent(event)

-    def keyPressEvent(self, event):
+    def keyPressEvent(self, event: Any) -> None:
        # Esc cancels face-pick mode.
-        if self._pick_face_mode and event.key() == Qt.Key_Escape:
+        if self._pick_face_mode and event.key() == Qt.Key.Key_Escape:
            self.set_pick_face_mode(False)
            self.pickFaceCancelled.emit()
            return
+        # Esc cancels fillet pick mode.
+        if self._fillet_pick_mode and event.key() == Qt.Key.Key_Escape:
+            self.set_fillet_pick_mode(False)
+            self.filletPickCancelled.emit()
+            return
+        # Esc cancels chamfer pick mode.
+        if self._chamfer_pick_mode and event.key() == Qt.Key.Key_Escape:
+            self.set_chamfer_pick_mode(False)
+            self.chamferPickCancelled.emit()
+            return
+        # Esc cancels thread pick mode.
+        if self._thread_pick_mode and event.key() == Qt.Key.Key_Escape:
+            self.set_thread_pick_mode(False)
+            self.threadPickCancelled.emit()
+            return
        # Esc cancels connector pick mode.
-        if self._connector_pick_mode and event.key() == Qt.Key_Escape:
+        if self._connector_pick_mode and event.key() == Qt.Key.Key_Escape:
            self.set_connector_pick_mode(False)
            self.connectorPickCancelled.emit()
            return
        # Esc cancels assembly move mode.
-        if self._assembly_move_mode and event.key() == Qt.Key_Escape:
+        if self._assembly_move_mode and event.key() == Qt.Key.Key_Escape:
            self.set_assembly_move_mode(False)
            return
+        # Esc cancels explicit sketch-gizmo pick mode.
+        if self._sketch_gizmo_pick_mode and event.key() == Qt.Key.Key_Escape:
+            self.set_sketch_gizmo_pick_mode(False)
+            self.sketchGizmoCancelled.emit()
+            return
        # Navigation shortcuts (lowercase = view presets, F = fit,
        # P/O = perspective/orthographic, R = reset).
        self._ensure_initialized()
@@ -1,7 +1,6 @@
 """Tests for Fluency CAD geometry kernel."""

 import pytest
-import numpy as np

 from fluency.geometry_occ.kernel import OCGeometryKernel, OCCGeometryObject
 from fluency.geometry_occ.sketch import OCCSketch
@@ -195,10 +194,14 @@ class TestOCCSketch:
        sk = OCCSketch()
        sk.set_workplane((10.0, 0.0, 5.0), normal, x_dir)
        # 20x20 square in UV
-        p0 = sk.add_point(-10, -10); p1 = sk.add_point(10, -10)
-        p2 = sk.add_point(10, 10);   p3 = sk.add_point(-10, 10)
-        sk.add_line(p0, p1); sk.add_line(p1, p2)
-        sk.add_line(p2, p3); sk.add_line(p3, p0)
+        p0 = sk.add_point(-10, -10)
+        p1 = sk.add_point(10, -10)
+        p2 = sk.add_point(10, 10)
+        p3 = sk.add_point(-10, 10)
+        sk.add_line(p0, p1)
+        sk.add_line(p1, p2)
+        sk.add_line(p2, p3)
+        sk.add_line(p3, p0)

        geom = sk.get_geometry()
        # The face must carry the plane normal for the kernel.
@@ -220,10 +223,14 @@ class TestOCCSketch:

        sk = OCCSketch()
        sk.set_workplane((0, 0, 0), (0, 0, 1), (1, 0, 0))
-        a = sk.add_point(-10, -10); b = sk.add_point(10, -10)
-        c = sk.add_point(10, 10);   d = sk.add_point(-10, 10)
-        sk.add_line(a, b); sk.add_line(b, c)
-        sk.add_line(c, d); sk.add_line(d, a)
+        a = sk.add_point(-10, -10)
+        b = sk.add_point(10, -10)
+        c = sk.add_point(10, 10)
+        d = sk.add_point(-10, 10)
+        sk.add_line(a, b)
+        sk.add_line(b, c)
+        sk.add_line(c, d)
+        sk.add_line(d, a)
        ctr = sk.add_point(0, 0)
        sk.add_circle(ctr, 3.0)

@@ -290,10 +297,14 @@ class TestExternalEntities:
        # Underlay: a 20x20 square projected from a face (closed polyline).
        sk.add_external_polyline([(0, 0), (20, 0), (20, 20), (0, 20), (0, 0)])
        # User profile: a 5x5 square — this is what should be extruded.
-        a = sk.add_point(2, 2); b = sk.add_point(8, 2)
-        c = sk.add_point(8, 8); d = sk.add_point(2, 8)
-        sk.add_line(a, b); sk.add_line(b, c)
-        sk.add_line(c, d); sk.add_line(d, a)
+        a = sk.add_point(2, 2)
+        b = sk.add_point(8, 2)
+        c = sk.add_point(8, 8)
+        d = sk.add_point(2, 8)
+        sk.add_line(a, b)
+        sk.add_line(b, c)
+        sk.add_line(c, d)
+        sk.add_line(d, a)
        faces = sk.detect_faces()
        # Only the user-drawn face (5x5 square) should be detected.
        assert len(faces) == 1
@@ -310,10 +321,14 @@ class TestExternalEntities:
    def test_external_entities_excluded_from_get_polygon_points(self):
        sk = OCCSketch()
        sk.add_external_polyline([(0, 0), (100, 0), (100, 100), (0, 100), (0, 0)])
-        a = sk.add_point(1, 1); b = sk.add_point(2, 1)
-        c = sk.add_point(2, 2); d = sk.add_point(1, 2)
-        sk.add_line(a, b); sk.add_line(b, c)
-        sk.add_line(c, d); sk.add_line(d, a)
+        a = sk.add_point(1, 1)
+        b = sk.add_point(2, 1)
+        c = sk.add_point(2, 2)
+        d = sk.add_point(1, 2)
+        sk.add_line(a, b)
+        sk.add_line(b, c)
+        sk.add_line(c, d)
+        sk.add_line(d, a)
        poly = sk.get_polygon_points()
        # The user square (1..2 range) should appear, not the 0..100 underlay.
        assert all(1.0 <= p.x <= 2.0 for p in poly)
@@ -328,10 +343,14 @@ class TestExternalEntities:
        # Underlay (NOT to be extruded).
        sk.add_external_polyline([(0, 0), (10, 0), (10, 10), (0, 10), (0, 0)])
        # User profile: a 2x2 square inside the underlay.
-        a = sk.add_point(1, 1); b = sk.add_point(3, 1)
-        c = sk.add_point(3, 3); d = sk.add_point(1, 3)
-        sk.add_line(a, b); sk.add_line(b, c)
-        sk.add_line(c, d); sk.add_line(d, a)
+        a = sk.add_point(1, 1)
+        b = sk.add_point(3, 1)
+        c = sk.add_point(3, 3)
+        d = sk.add_point(1, 3)
+        sk.add_line(a, b)
+        sk.add_line(b, c)
+        sk.add_line(c, d)
+        sk.add_line(d, a)
        geom = sk.get_geometry()
        # Volume = 2 * 2 * 4 = 16, NOT 10 * 10 * 4 = 400.
        kernel = OCGeometryKernel()
@@ -498,10 +517,9 @@ class TestExtrudeCutFix:
        and the tool is no longer needed.
        """
        from OCP.BRepPrimAPI import BRepPrimAPI_MakeBox
-        from fluency.geometry_occ.kernel import OCGeometryKernel, OCCGeometryObject
+        from fluency.geometry_occ.kernel import OCGeometryKernel
        from OCP.GProp import GProp_GProps
        from OCP.BRepGProp import BRepGProp
-        import math

        k = OCGeometryKernel()
        target_shape = BRepPrimAPI_MakeBox(100, 100, 100).Shape()
@@ -511,17 +529,18 @@ class TestExtrudeCutFix:
        # expected volume easy to compute.
        from OCP.BRepPrimAPI import BRepPrimAPI_MakePrism
        from OCP.gp import gp_Pnt, gp_Vec
+
        # 20x20 square at (0,0,0), extruded along +Z by 200.
        from OCP.BRepBuilderAPI import BRepBuilderAPI_MakePolygon
+
        mp = BRepBuilderAPI_MakePolygon()
-        for (x, y) in [(0, 0), (20, 0), (20, 20), (0, 20)]:
+        for x, y in [(0, 0), (20, 0), (20, 20), (0, 20)]:
            mp.Add(gp_Pnt(x, y, 0))
        mp.Close()
        from OCP.BRepBuilderAPI import BRepBuilderAPI_MakeFace
+
        face = BRepBuilderAPI_MakeFace(mp.Wire()).Face()
-        tool_shape = BRepPrimAPI_MakePrism(
-            face, gp_Vec(0, 0, 200)
-        ).Shape()
+        tool_shape = BRepPrimAPI_MakePrism(face, gp_Vec(0, 0, 200)).Shape()
        tool_obj = OCCGeometryObject(tool_shape, {"type": "prism"})

        # Before cut: target is 100^3 = 1_000_000.
@@ -536,9 +555,7 @@ class TestExtrudeCutFix:
        # After cut: target is 1_000_000 - 20*20*100 = 960_000
        # (the prism only intersects the box in z=[0,100], i.e. 100 deep).
        g1 = GProp_GProps()
-        BRepGProp.VolumeProperties_s(
-            k._get_shape(target_obj_geometry), g1
-        )
+        BRepGProp.VolumeProperties_s(k._get_shape(target_obj_geometry), g1)
        assert abs(g1.Mass() - 960_000.0) < 1.0

    def test_boolean_difference_does_not_leave_separate_cavity_body(self):
@@ -551,10 +568,9 @@ class TestExtrudeCutFix:
        target, so a single body remains.
        """
        from OCP.BRepPrimAPI import BRepPrimAPI_MakeBox
-        from OCP.BRepAlgoAPI import BRepAlgoAPI_Cut
        from OCP.TopExp import TopExp_Explorer
        from OCP.TopAbs import TopAbs_SOLID
-        from fluency.geometry_occ.kernel import OCGeometryKernel, OCCGeometryObject
+        from fluency.geometry_occ.kernel import OCGeometryKernel

        k = OCGeometryKernel()
        target_shape = BRepPrimAPI_MakeBox(100, 100, 100).Shape()
@@ -562,6 +578,7 @@ class TestExtrudeCutFix:

        # Tool: small box at the centre, fully inside the target.
        from OCP.BRepPrimAPI import BRepPrimAPI_MakeBox as BBox
+
        tool_shape = BBox(20, 20, 20).Shape()
        tool_obj = OCCGeometryObject(tool_shape, {})

@@ -595,91 +612,59 @@ class TestBodyVisibilityToggle:

    def _make_window(self):
        import os
+
        os.environ.setdefault("QT_QPA_PLATFORM", "offscreen")
        from PySide6.QtWidgets import QApplication
+
        app = QApplication.instance() or QApplication([])
        from fluency.main import MainWindow
+
        return MainWindow()

    def test_body_list_uses_checkable_items(self):
-        """Each body list item must be a checkable QListWidgetItem."""
+        """Each body list item has a data role for the toggle handler."""
        from PySide6.QtCore import Qt
+
        win = self._make_window()
        # Add a fake body to the current component so the list isn't empty.
        from fluency.models.data_model import Body
        from OCP.BRepPrimAPI import BRepPrimAPI_MakeBox
-        from fluency.geometry_occ.kernel import OCCGeometryObject
-        box = OCCGeometryObject(
-            BRepPrimAPI_MakeBox(10, 10, 10).Shape(), {}
-        )
+
+        box = OCCGeometryObject(BRepPrimAPI_MakeBox(10, 10, 10).Shape(), {})
        win._current_component.bodies["a"] = Body(name="A", geometry=box)
        win._refresh_lists()
        items = win._body_list.findItems("A", Qt.MatchExactly)
        assert len(items) == 1
-        # Item is checkable (so the user can toggle visibility).
-        assert items[0].flags() & Qt.ItemIsUserCheckable
        # And the body id is stored on the item for the toggle handler.
        assert items[0].data(Qt.UserRole) == "a"
-        # Default state is checked (= visible).
-        assert items[0].checkState() == Qt.Checked
+        # Default state is visible.
+        assert win._current_component.bodies["a"].visible is True

    def test_toggling_visibility_updates_body_model(self):
-        """Flipping the checkbox should set body.visible accordingly."""
+        """Toggling visibility via _on_body_visibility_changed updates the model."""
        from PySide6.QtCore import Qt
+
        win = self._make_window()
        from fluency.models.data_model import Body
        from OCP.BRepPrimAPI import BRepPrimAPI_MakeBox
-        from fluency.geometry_occ.kernel import OCCGeometryObject
-        box = OCCGeometryObject(
-            BRepPrimAPI_MakeBox(10, 10, 10).Shape(), {}
-        )
+
+        box = OCCGeometryObject(BRepPrimAPI_MakeBox(10, 10, 10).Shape(), {})
        win._current_component.bodies["a"] = Body(name="A", geometry=box)
        win._refresh_lists()
        item = win._body_list.findItems("A", Qt.MatchExactly)[0]

        # Toggle off.
-        item.setCheckState(Qt.Unchecked)
        win._on_body_visibility_changed(item)
        assert win._current_component.bodies["a"].visible is False

        # Toggle back on.
-        item.setCheckState(Qt.Checked)
        win._on_body_visibility_changed(item)
        assert win._current_component.bodies["a"].visible is True

-    def test_visibility_no_op_when_unchanged(self):
-        """Re-emitting the same state must not trigger a viewer call.
-
-        The set_visibility call into the viewer is cheap but not free;
-        spamming it on every selection change would be wasteful.  The
-        handler short-circuits when the new state matches the model's.
-        """
-        from PySide6.QtCore import Qt
-        win = self._make_window()
-        from fluency.models.data_model import Body
-        from OCP.BRepPrimAPI import BRepPrimAPI_MakeBox
-        from fluency.geometry_occ.kernel import OCCGeometryObject
-        box = OCCGeometryObject(
-            BRepPrimAPI_MakeBox(10, 10, 10).Shape(), {}
-        )
-        win._current_component.bodies["a"] = Body(name="A", geometry=box)
-        win._refresh_lists()
-        item = win._body_list.findItems("A", Qt.MatchExactly)[0]
-
-        # Force the model's visibility to False to mimic a desync.
-        win._current_component.bodies["a"].visible = False
-        # Set the checkbox to Unchecked — this matches the model, so the
-        # handler should short-circuit (not call set_visibility).
-        item.setCheckState(Qt.Unchecked)
-        # We can't directly assert "viewer was not called" without
-        # monkey-patching; instead assert that re-firing the handler
-        # doesn't raise and the state is consistent.
-        win._on_body_visibility_changed(item)
-        assert win._current_component.bodies["a"].visible is False
-

 def math_hypot(x, y):
    import math
+
    return math.hypot(x, y)


@@ -698,10 +683,13 @@ class TestConstraintTagRendering:
    def _make_widget_with_sketch(self, sk):
        """Build a Sketch2DWidget in offscreen mode and attach *sk* to it."""
        import os
+
        os.environ.setdefault("QT_QPA_PLATFORM", "offscreen")
        from PySide6.QtWidgets import QApplication
+
        app = QApplication.instance() or QApplication([])
        from fluency.main import Sketch2DWidget
+
        w = Sketch2DWidget()
        w.set_sketch(sk)
        return w
@@ -824,6 +812,7 @@ class TestConstraintTagRendering:
        class _BadRound:
            def __round__(self, ndigits=0):
                raise TypeError("cannot round")
+
        sk._entities[c.id].geometry = (_BadRound(), _BadRound())
        tags = w._compute_constraint_tags()
        assert all(t["center"] is not None for t in tags)
@@ -865,12 +854,13 @@ class TestExtrudeRedesign:

    def _make_window_with_box(self, box_side=100.0):
        import os
+
        os.environ.setdefault("QT_QPA_PLATFORM", "offscreen")
        from PySide6.QtWidgets import QApplication
+
        app = QApplication.instance() or QApplication([])
        from fluency.main import MainWindow
        from fluency.models.data_model import Sketch, Body
-        from fluency.geometry_occ.kernel import OCCGeometryObject
        from fluency.geometry_occ.sketch import OCCSketch
        from OCP.BRepPrimAPI import BRepPrimAPI_MakeBox

@@ -896,7 +886,6 @@ class TestExtrudeRedesign:
        return win, sketch, sk, box_obj

    def _add_circle(self, sk, r=10.0):
-        from fluency.geometry_occ.sketch import OCCSketch
        c = sk.add_point(0, 0)
        sk.add_circle(c, r)
        sk.solve()
@@ -905,6 +894,7 @@ class TestExtrudeRedesign:
    def _geometry_volume(self, win, geom):
        from OCP.GProp import GProp_GProps
        from OCP.BRepGProp import BRepGProp
+
        sh = win._kernel._get_shape(geom)
        g = GProp_GProps()
        BRepGProp.VolumeProperties_s(sh, g)
@@ -919,37 +909,48 @@ class TestExtrudeRedesign:
        so a 5 mm cut makes a real 5 mm-deep pocket.
        """
        import math
+
        win, sketch, sk, box_obj = self._make_window_with_box(100.0)
        face_geom = self._add_circle(sk, r=10.0)
        # Plain cut, length=5, NOT inverted.  Pre-redesign this would have
        # removed nothing; post-redesign it must remove a 5 mm cylinder.
        result = win._compute_extrude_result(
-            sketch, face_geom,
-            length=5.0, symmetric=False, invert=False,
-            cut=True, union=False, through_all=False,
+            sketch,
+            face_geom,
+            length=5.0,
+            symmetric=False,
+            invert=False,
+            cut=True,
+            union=False,
+            through_all=False,
        )
        assert result is not None
        assert result["target_body"] is not None
        assert result["target_body"].name == "Box1"
        vol = self._geometry_volume(win, result["result_geom"])
-        expected = 100.0 ** 3 - math.pi * (10.0 ** 2) * 5.0
+        expected = 100.0**3 - math.pi * (10.0**2) * 5.0
        assert abs(vol - expected) < 1.0

    def test_cut_through_all_passes_through(self):
-        """"Through All" cut fully passes through the body."""
+        """ "Through All" cut fully passes through the body."""
        import math
+
        win, sketch, sk, box_obj = self._make_window_with_box(100.0)
        face_geom = self._add_circle(sk, r=10.0)
        result = win._compute_extrude_result(
-            sketch, face_geom,
+            sketch,
+            face_geom,
            length=5.0,  # ignored when through_all
-            symmetric=False, invert=False,
-            cut=True, union=False, through_all=True,
+            symmetric=False,
+            invert=False,
+            cut=True,
+            union=False,
+            through_all=True,
        )
        assert result is not None
        vol = self._geometry_volume(win, result["result_geom"])
        # Full through cylinder = pi * r^2 * box_depth.
-        expected = 100.0 ** 3 - math.pi * (10.0 ** 2) * 100.0
+        expected = 100.0**3 - math.pi * (10.0**2) * 100.0
        assert abs(vol - expected) < 1.0

    def test_cut_auto_targets_source_body_not_existing_zero(self):
@@ -960,30 +961,23 @@ class TestExtrudeRedesign:
        """
        import math
        import os
+
        os.environ.setdefault("QT_QPA_PLATFORM", "offscreen")
        from PySide6.QtWidgets import QApplication
+
        app = QApplication.instance() or QApplication([])
        from fluency.main import MainWindow
        from fluency.models.data_model import Sketch, Body
-        from fluency.geometry_occ.kernel import OCCGeometryObject
        from fluency.geometry_occ.sketch import OCCSketch
        from OCP.BRepPrimAPI import BRepPrimAPI_MakeBox

        win = MainWindow()
        # First body in the dict: a 50-millimetre box ALSO.
-        first = OCCGeometryObject(
-            BRepPrimAPI_MakeBox(50, 50, 50).Shape(), {}
-        )
-        win._current_component.bodies["first"] = Body(
-            name="First", geometry=first
-        )
+        first = OCCGeometryObject(BRepPrimAPI_MakeBox(50, 50, 50).Shape(), {})
+        win._current_component.bodies["first"] = Body(name="First", geometry=first)
        # Source body: a 100-millimetre box (drawn over).
-        src = OCCGeometryObject(
-            BRepPrimAPI_MakeBox(100, 100, 100).Shape(), {}
-        )
-        win._current_component.bodies["src"] = Body(
-            name="Src", geometry=src
-        )
+        src = OCCGeometryObject(BRepPrimAPI_MakeBox(100, 100, 100).Shape(), {})
+        win._current_component.bodies["src"] = Body(name="Src", geometry=src)
        # Sketch circle on top of the SOURCE box (0,0 so normal +Z).
        sk = OCCSketch()
        sk.set_workplane((50, 50, 100), (0, 0, 1), (1, 0, 0))
@@ -999,16 +993,21 @@ class TestExtrudeRedesign:

        face_geom = sk.get_geometry()
        result = win._compute_extrude_result(
-            sketch, face_geom,
-            length=5.0, symmetric=False, invert=False,
-            cut=True, union=False, through_all=True,
+            sketch,
+            face_geom,
+            length=5.0,
+            symmetric=False,
+            invert=False,
+            cut=True,
+            union=False,
+            through_all=True,
        )
        assert result is not None
        # Target is the source box, NOT the dict's first body.
        assert result["target_body"].name == "Src"
        vol = self._geometry_volume(win, result["result_geom"])
        # 100^3 - pi*100*100 (through-all full-depth cut on the 100 box).
-        expected = 100.0 ** 3 - math.pi * (10.0 ** 2) * 100.0
+        expected = 100.0**3 - math.pi * (10.0**2) * 100.0
        assert abs(vol - expected) < 1.0

    def test_union_default_builds_outward(self):
@@ -1019,17 +1018,23 @@ class TestExtrudeRedesign:
        rather than "subtracting" from the existing box.
        """
        import math
+
        win, sketch, sk, box_obj = self._make_window_with_box(100.0)
        face_geom = self._add_circle(sk, r=10.0)
        result = win._compute_extrude_result(
-            sketch, face_geom,
-            length=10.0, symmetric=False, invert=False,
-            cut=False, union=True, through_all=False,
+            sketch,
+            face_geom,
+            length=10.0,
+            symmetric=False,
+            invert=False,
+            cut=False,
+            union=True,
+            through_all=False,
        )
        assert result is not None
        vol = self._geometry_volume(win, result["result_geom"])
        # 100^3 + pi*100*10 — material added on top.
-        expected = 100.0 ** 3 + math.pi * (10.0 ** 2) * 10.0
+        expected = 100.0**3 + math.pi * (10.0**2) * 10.0
        assert abs(vol - expected) < 1.0

    def test_plain_extrude_untouched_by_source_body(self):
@@ -1037,9 +1042,14 @@ class TestExtrudeRedesign:
        win, sketch, sk, box_obj = self._make_window_with_box(100.0)
        face_geom = self._add_circle(sk, r=10.0)
        result = win._compute_extrude_result(
-            sketch, face_geom,
-            length=10.0, symmetric=False, invert=False,
-            cut=False, union=False, through_all=False,
+            sketch,
+            face_geom,
+            length=10.0,
+            symmetric=False,
+            invert=False,
+            cut=False,
+            union=False,
+            through_all=False,
        )
        assert result is not None
        # No boolean target; result is the standalone tool extrusion.
@@ -1047,7 +1057,8 @@ class TestExtrudeRedesign:
        vol = self._geometry_volume(win, result["result_geom"])
        # Standalone cylinder 10 mm tall.
        import math
-        assert abs(vol - math.pi * (10.0 ** 2) * 10.0) < 1.0
+
+        assert abs(vol - math.pi * (10.0**2) * 10.0) < 1.0

    def test_freshly_picked_sketch_is_auto_selected(self):
        """After _on_face_picked, the new sketch is the current list row.
@@ -1055,7 +1066,6 @@ class TestExtrudeRedesign:
        The user should be able to click Extrude/Cut immediately without
        first hunting for the new sketch in the left list.
        """
-        from fluency.geometry_occ.kernel import OCCGeometryObject
        win, _, sk, box_obj = self._make_window_with_box(100.0)
        # Simulate _on_face_picked by calling it through a fake face
        # shape — but the simplest behavioural check is to call the
@@ -1063,6 +1073,7 @@ class TestExtrudeRedesign:
        # set as _current_sketch, and it appears (and is selected) in
        # the list after _refresh_lists + setCurrentRow.
        from fluency.models.data_model import Sketch
+
        sketch = Sketch(name="Sketch on face 99")
        sketch._source_body_id = "b1"
        sketch.set_workplane((50, 50, 100), (0, 0, 1), (1, 0, 0))
@@ -1084,8 +1095,10 @@ class TestExtrudeRedesign:
    def test_preview_callback_invoked_on_value_change(self):
        """The live preview callback fires on spinbox/checkbox changes."""
        import os
+
        os.environ.setdefault("QT_QPA_PLATFORM", "offscreen")
        from PySide6.QtWidgets import QApplication
+
        app = QApplication.instance() or QApplication([])
        from fluency.main import ExtrudeDialog

@@ -1110,8 +1123,10 @@ class TestExtrudeRedesign:
    def test_preview_hidden_event_sends_none(self):
        """hideEvent should deliver None to the callback so the host clears."""
        import os
+
        os.environ.setdefault("QT_QPA_PLATFORM", "offscreen")
        from PySide6.QtWidgets import QApplication
+
        app = QApplication.instance() or QApplication([])
        from fluency.main import ExtrudeDialog
Author	SHA1	Message	Date
bklronin	1e9b0cab1c	- arc improvements, fillets, operations, bodys	2026-08-05 16:47:25 +02:00
bklronin	a7e7a9f2c3	- arc improvements, fillets, operations, bodys	2026-08-05 09:44:17 +02:00
bklronin	48042659fc	- arc improvements, fillets, operations, bodys	2026-08-02 22:04:57 +02:00
bklronin	baa2fd5d47	- added "measurement lines"	2026-08-02 20:58:43 +02:00
bklronin	0daa6152ee	- added "measurement lines"	2026-07-26 21:39:47 +02:00