brepkit-operations 3.2.22

#![allow(
    clippy::unwrap_used,
    clippy::expect_used,
    clippy::print_stderr,
    deprecated
)]

use std::collections::{HashMap, HashSet};

use brepkit_math::nurbs::surface::NurbsSurface;
use brepkit_math::vec::Point3;
use brepkit_topology::Topology;
use brepkit_topology::edge::EdgeId;
use brepkit_topology::face::{FaceId, FaceSurface};
use brepkit_topology::solid::SolidId;
use brepkit_topology::test_utils::make_unit_cube_manifold;
use brepkit_topology::validation::validate_shell_manifold;

use crate::test_helpers::assert_euler_genus0;

use super::*;

fn solid_edge_ids(topo: &Topology, solid_id: SolidId) -> Vec<EdgeId> {
    let solid = topo.solid(solid_id).expect("test solid");
    let shell = topo.shell(solid.outer_shell()).expect("test shell");
    let mut seen = HashSet::new();
    let mut edges = Vec::new();
    for &fid in shell.faces() {
        let face = topo.face(fid).expect("test face");
        let wire = topo.wire(face.outer_wire()).expect("test wire");
        for oe in wire.edges() {
            if seen.insert(oe.edge().index()) {
                edges.push(oe.edge());
            }
        }
    }
    edges
}

#[test]
fn fillet_single_edge() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);

    let edges = solid_edge_ids(&topo, cube);
    let target = edges[0];

    let result = fillet(&mut topo, cube, &[target], 0.1).expect("fillet should succeed");

    let s = topo.solid(result).expect("result solid");
    let sh = topo.shell(s.outer_shell()).expect("shell");

    // 6 original + 1 fillet = 7 faces
    assert_eq!(
        sh.faces().len(),
        7,
        "expected 7 faces after single-edge fillet"
    );
}

#[test]
fn fillet_single_edge_euler() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);
    let edges = solid_edge_ids(&topo, cube);
    let result = fillet(&mut topo, cube, &[edges[0]], 0.1).expect("fillet should succeed");
    assert_euler_genus0(&topo, result);
}

#[test]
fn fillet_result_is_manifold() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);

    let edges = solid_edge_ids(&topo, cube);
    let result = fillet(&mut topo, cube, &[edges[0]], 0.1).expect("fillet should succeed");

    let s = topo.solid(result).expect("result solid");
    let sh = topo.shell(s.outer_shell()).expect("shell");
    validate_shell_manifold(sh, &topo).expect("fillet result should be manifold");
}

#[test]
fn fillet_zero_radius_error() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);
    let edges = solid_edge_ids(&topo, cube);
    assert!(fillet(&mut topo, cube, &[edges[0]], 0.0).is_err());
}

#[test]
fn fillet_negative_radius_error() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);
    let edges = solid_edge_ids(&topo, cube);
    assert!(fillet(&mut topo, cube, &[edges[0]], -0.1).is_err());
}

#[test]
fn fillet_no_edges_error() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);
    assert!(fillet(&mut topo, cube, &[], 0.1).is_err());
}

#[test]
fn radius_law_constant() {
    let law = FilletRadiusLaw::Constant(0.5);
    assert!((law.evaluate(0.0) - 0.5).abs() < 1e-10);
    assert!((law.evaluate(0.5) - 0.5).abs() < 1e-10);
    assert!((law.evaluate(1.0) - 0.5).abs() < 1e-10);
}

#[test]
fn radius_law_linear() {
    let law = FilletRadiusLaw::Linear {
        start: 0.1,
        end: 0.5,
    };
    assert!((law.evaluate(0.0) - 0.1).abs() < 1e-10);
    assert!((law.evaluate(0.5) - 0.3).abs() < 1e-10);
    assert!((law.evaluate(1.0) - 0.5).abs() < 1e-10);
}

#[test]
fn radius_law_scurve() {
    let law = FilletRadiusLaw::SCurve {
        start: 0.1,
        end: 0.5,
    };
    // S-curve should match endpoints
    assert!((law.evaluate(0.0) - 0.1).abs() < 1e-10);
    assert!((law.evaluate(1.0) - 0.5).abs() < 1e-10);
    // Midpoint should be between start and end
    let mid = law.evaluate(0.5);
    assert!(mid > 0.1 && mid < 0.5);
}

#[test]
fn fillet_variable_constant_law() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);

    let edges = solid_edge_ids(&topo, cube);
    let laws = vec![(edges[0], FilletRadiusLaw::Constant(0.1))];

    let result = fillet_variable(&mut topo, cube, &laws).expect("variable fillet should work");

    let s = topo.solid(result).expect("result solid");
    let sh = topo.shell(s.outer_shell()).expect("shell");
    assert_eq!(sh.faces().len(), 7, "should have 7 faces after fillet");
}

#[test]
fn fillet_variable_linear_law() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);

    let edges = solid_edge_ids(&topo, cube);
    let laws = vec![(
        edges[0],
        FilletRadiusLaw::Linear {
            start: 0.05,
            end: 0.15,
        },
    )];

    let result = fillet_variable(&mut topo, cube, &laws).expect("variable fillet should work");

    let vol = crate::measure::solid_volume(&topo, result, 0.1).unwrap();
    assert!(vol > 0.5, "filleted cube should have volume, got {vol}");
}

#[test]
fn fillet_variable_removes_material_linear_law() {
    let mut topo = Topology::new();
    let solid = crate::primitives::make_box(&mut topo, 10.0, 10.0, 10.0).unwrap();
    let edges = solid_edge_ids(&topo, solid);
    let laws = vec![(
        edges[0],
        FilletRadiusLaw::Linear {
            start: 0.5,
            end: 1.5,
        },
    )];
    let result = fillet_variable(&mut topo, solid, &laws).expect("variable fillet");
    let vol = crate::measure::solid_volume(&topo, result, 0.05).unwrap();
    assert!(vol < 1000.0, "fillet must remove material, got {vol}");
    assert!(
        vol > 900.0,
        "single-edge fillet removes only a sliver, got {vol}"
    );

    let s = topo.solid(result).expect("result solid");
    let sh = topo.shell(s.outer_shell()).expect("shell");
    validate_shell_manifold(sh, &topo).expect("variable fillet result should be manifold");
    assert_euler_genus0(&topo, result);
}

#[test]
fn fillet_has_positive_volume() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);

    let edges = solid_edge_ids(&topo, cube);
    let result = fillet(&mut topo, cube, &[edges[0]], 0.1).expect("fillet should succeed");

    let vol = crate::measure::solid_volume(&topo, result, 0.1).unwrap();
    assert!(
        vol > 0.5,
        "filleted cube should have significant volume, got {vol}"
    );
}

#[test]
fn rolling_ball_fillet_single_edge() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);

    let edges = solid_edge_ids(&topo, cube);
    let result = fillet_rolling_ball(&mut topo, cube, &[edges[0]], 0.1)
        .expect("rolling-ball fillet should succeed");

    let s = topo.solid(result).expect("result solid");
    let sh = topo.shell(s.outer_shell()).expect("shell");

    // 6 original faces + 1 NURBS fillet = 7 faces
    assert_eq!(
        sh.faces().len(),
        7,
        "expected 7 faces after single-edge rolling-ball fillet"
    );

    // Rolling-ball fillet on a box should still be genus-0 (χ=2).
    assert_euler_genus0(&topo, result);
}

#[test]
fn rolling_ball_rejects_closed_rim_so_dispatcher_falls_through() {
    // The degeneracy guard's whole purpose: a cylinder's closed circular rim
    // collapses its blend strip to zero area, and `try_fillet` relies on the
    // error to fall through to the walking engine. The guard clears healthy
    // faces via a cheap boundary-polygon area, so this pins that the shortcut
    // cannot accept a collapsed face and silently ship the corrupt solid.
    let mut topo = Topology::new();
    let cyl = crate::primitives::make_cylinder(&mut topo, 10.0, 20.0).expect("cylinder");
    let edges = solid_edge_ids(&topo, cyl);

    let err = fillet_rolling_ball(&mut topo, cyl, &edges, 0.5)
        .expect_err("rolling-ball must reject a closed circular rim");
    let reason = match &err {
        crate::OperationsError::InvalidInput { reason } => reason,
        other => unreachable!("expected InvalidInput from the degeneracy guard, got: {other:?}"),
    };
    assert!(
        reason.contains("degenerate face"),
        "expected the degeneracy guard to fire, got: {reason}"
    );
}

#[test]
fn rolling_ball_straight_edge_wall_is_exact_cylinder() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);

    let edges = solid_edge_ids(&topo, cube);
    let result = fillet_rolling_ball(&mut topo, cube, &[edges[0]], 0.1)
        .expect("rolling-ball fillet should succeed");

    let s = topo.solid(result).expect("result solid");
    let sh = topo.shell(s.outer_shell()).expect("shell");

    // A straight edge between two planar faces rolls an EXACT quarter-cylinder,
    // so the blend wall must be a Cylinder, not a NURBS approximation of one.
    // Degrading it to NURBS costs downstream booleans their analytic path and
    // makes the wall tessellate far denser than its curvature warrants.
    let walls: Vec<_> = sh
        .faces()
        .iter()
        .filter(|&&fid| !topo.face(fid).expect("face").surface().is_planar())
        .collect();
    assert_eq!(walls.len(), 1, "one blend wall expected");
    let surface = topo.face(*walls[0]).expect("face").surface();
    assert!(
        matches!(surface, FaceSurface::Cylinder(cyl) if (cyl.radius() - 0.1).abs() < 1e-9),
        "straight-edge blend wall must be an exact r=0.1 Cylinder, got {:?}",
        surface.type_tag()
    );
}

#[test]
fn rolling_ball_fillet_surface_is_circular_arc() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);

    let edges = solid_edge_ids(&topo, cube);
    let result = fillet_rolling_ball(&mut topo, cube, &[edges[0]], 0.2)
        .expect("rolling-ball fillet should succeed");

    let s = topo.solid(result).expect("result solid");
    let sh = topo.shell(s.outer_shell()).expect("shell");

    // Find the NURBS fillet face and verify it's a proper circular arc.
    for &fid in sh.faces() {
        let face = topo.face(fid).expect("face");
        if let FaceSurface::Nurbs(surface) = face.surface() {
            // The surface should be degree (2, 1) — circular arc × linear.
            assert_eq!(
                surface.degree_u(),
                2,
                "u (arc) direction should be degree 2"
            );
            assert_eq!(
                surface.degree_v(),
                1,
                "v (extrusion) direction should be degree 1"
            );

            // Evaluate at the midpoint (u=0.5, v=0.5) and check that
            // the point is at distance R from both adjacent faces.
            let mid_pt = surface.evaluate(0.5, 0.5);

            // For a unit cube, the fillet point should be inside the cube
            // (all coordinates between -0.1 and 1.1 for radius 0.2).
            assert!(
                mid_pt.x() > -0.5 && mid_pt.x() < 1.5,
                "fillet midpoint x should be near cube: {mid_pt:?}"
            );
        }
    }
}

#[test]
fn rolling_ball_fillet_positive_volume() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);

    let edges = solid_edge_ids(&topo, cube);
    let result =
        fillet_rolling_ball(&mut topo, cube, &[edges[0]], 0.1).expect("fillet should succeed");

    let vol = crate::measure::solid_volume(&topo, result, 0.1).unwrap();
    assert!(
        vol > 0.5,
        "filleted cube should have significant volume, got {vol}"
    );
}

#[test]
fn rolling_ball_fillet_multiple_edges() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);

    let edges = solid_edge_ids(&topo, cube);
    // edges[0] and edges[1] share a corner vertex.
    let result = fillet_rolling_ball(&mut topo, cube, &[edges[0], edges[1]], 0.1)
        .expect("multi-edge rolling-ball fillet should succeed");

    let s = topo.solid(result).expect("result solid");
    let sh = topo.shell(s.outer_shell()).expect("shell");

    // 6 trimmed planar + 2 NURBS fillet strips + 1 corner patch (the two
    // edges share a corner) = 9 faces.
    assert_eq!(
        sh.faces().len(),
        9,
        "expected 9 faces after two-edge shared-corner rolling-ball fillet"
    );
    validate_shell_manifold(sh, &topo).expect("two-edge fillet should be manifold");
}

/// Regression for #841: filleting two edges that share a corner vertex in a
/// single rolling-ball pass must produce a watertight (closed, euler-2) solid.
/// Previously the corner gap was left open (4 free edges, euler=1) because the
/// strips were set back but no corner patch closed the junction and the side
/// faces collapsed the unfilleted edge onto the far corner.
#[test]
fn rolling_ball_two_edges_shared_corner_watertight() {
    // Collect every pair of box edges that share a vertex, then fillet a sample.
    let mut topo = Topology::new();
    let cube = crate::primitives::make_box(&mut topo, 10.0, 10.0, 10.0).unwrap();
    let all_edges = solid_edge_ids(&topo, cube);

    // Find pairs of edges that share a vertex (a corner).
    let mut shared_pairs: Vec<(usize, usize)> = Vec::new();
    for i in 0..all_edges.len() {
        for j in (i + 1)..all_edges.len() {
            let ei = topo.edge(all_edges[i]).unwrap();
            let ej = topo.edge(all_edges[j]).unwrap();
            let shares = ei.start() == ej.start()
                || ei.start() == ej.end()
                || ei.end() == ej.start()
                || ei.end() == ej.end();
            if shares {
                shared_pairs.push((i, j));
            }
        }
    }
    assert!(
        !shared_pairs.is_empty(),
        "box should have corner-sharing edge pairs"
    );

    // Verify the first several corner-sharing pairs (iteration order); capped to
    // keep the test fast while still exercising multiple corners.
    for &(i, j) in shared_pairs.iter().take(6) {
        let mut t = Topology::new();
        let box_id = crate::primitives::make_box(&mut t, 10.0, 10.0, 10.0).unwrap();
        let edges = solid_edge_ids(&t, box_id);
        let result = fillet_rolling_ball(&mut t, box_id, &[edges[i], edges[j]], 1.0)
            .expect("fillet of shared-corner edges should succeed");

        let s = t.solid(result).expect("result solid");
        let sh = t.shell(s.outer_shell()).expect("shell");
        assert!(
            brepkit_topology::validation::validate_shell_closed(sh, &t).is_ok(),
            "shared-corner pair {i},{j} should be watertight"
        );
        assert!(
            validate_shell_manifold(sh, &t).is_ok(),
            "shared-corner pair {i},{j} should be manifold"
        );
        assert_euler_genus0(&t, result);

        let vol = crate::measure::solid_volume(&t, result, 0.01).unwrap();
        assert!(
            (985.0..1000.0).contains(&vol),
            "shared-corner pair {i},{j}: volume {vol} outside sane range"
        );
    }
}

/// A box edge pair that does NOT share a corner must remain watertight too
/// (the corner patch must not fire spuriously).
#[test]
fn rolling_ball_two_edges_no_shared_corner_watertight() {
    let mut topo = Topology::new();
    let cube = crate::primitives::make_box(&mut topo, 10.0, 10.0, 10.0).unwrap();
    let edges = solid_edge_ids(&topo, cube);

    // Find a pair with no shared vertex.
    let mut pair = None;
    'outer: for i in 0..edges.len() {
        for j in (i + 1)..edges.len() {
            let ei = topo.edge(edges[i]).unwrap();
            let ej = topo.edge(edges[j]).unwrap();
            let shares = ei.start() == ej.start()
                || ei.start() == ej.end()
                || ei.end() == ej.start()
                || ei.end() == ej.end();
            if !shares {
                pair = Some((i, j));
                break 'outer;
            }
        }
    }
    let (i, j) = pair.expect("box should have a non-corner-sharing edge pair");

    let result = fillet_rolling_ball(&mut topo, cube, &[edges[i], edges[j]], 1.0)
        .expect("non-shared-corner fillet should succeed");
    let s = topo.solid(result).expect("result solid");
    let sh = topo.shell(s.outer_shell()).expect("shell");
    // 6 trimmed planar + 2 fillet strips = 8 faces, no corner patch.
    assert_eq!(sh.faces().len(), 8, "non-shared pair should add no patch");
    brepkit_topology::validation::validate_shell_closed(sh, &topo)
        .expect("non-shared-corner fillet should be watertight");
    assert_euler_genus0(&topo, result);
}

#[test]
fn rolling_ball_fillet_error_cases() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);
    let edges = solid_edge_ids(&topo, cube);

    assert!(fillet_rolling_ball(&mut topo, cube, &[edges[0]], 0.0).is_err());
    assert!(fillet_rolling_ball(&mut topo, cube, &[edges[0]], -0.1).is_err());
    assert!(fillet_rolling_ball(&mut topo, cube, &[], 0.1).is_err());
}

#[test]
fn vertex_blend_all_edges_box() {
    // Fillet all 12 edges of a unit cube → 8 vertex blend patches should
    // close the corners, giving a watertight mesh.
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);
    let edges = solid_edge_ids(&topo, cube);
    assert_eq!(edges.len(), 12, "unit cube should have 12 edges");

    let result =
        fillet_rolling_ball(&mut topo, cube, &edges, 0.1).expect("all-edges fillet should succeed");

    let s = topo.solid(result).expect("result solid");
    let sh = topo.shell(s.outer_shell()).expect("shell");

    // 6 trimmed planar faces + 12 NURBS fillet strips + 8 vertex blend triangles = 26
    assert_eq!(
        sh.faces().len(),
        26,
        "expected 26 faces (6 planar + 12 fillet + 8 blend)"
    );
}

#[test]
fn vertex_blend_all_edges_box_volume() {
    // Fillet all 12 edges of a 10×10×10 box at r=1.0. The result must be a
    // closed, manifold, genus-0 solid (26 faces) whose volume reflects only
    // the fillet-arc and corner-blend material removal — not gross corner
    // excision. Analytic expectation ≈ 975.6:
    //   1000 − 12·(1−π/4)·1²·8 (edge slivers ≈ 20.6)
    //        − 8·(1−π/6)·1³    (corner blends ≈ 3.8).
    let mut topo = Topology::new();
    let cube = crate::primitives::make_box(&mut topo, 10.0, 10.0, 10.0).unwrap();
    let edges = solid_edge_ids(&topo, cube);
    assert_eq!(edges.len(), 12, "box should have 12 edges");

    let result =
        fillet_rolling_ball(&mut topo, cube, &edges, 1.0).expect("all-edges fillet should succeed");

    let s = topo.solid(result).expect("result solid");
    let sh = topo.shell(s.outer_shell()).expect("shell");
    validate_shell_manifold(sh, &topo).expect("filleted box should be manifold");
    assert_euler_genus0(&topo, result);

    assert_eq!(
        sh.faces().len(),
        26,
        "expected 26 faces (6 planar + 12 fillet + 8 blend)"
    );

    let vol = crate::measure::solid_volume(&topo, result, 0.01).unwrap();
    assert!(
        vol > 974.0 && vol < 978.0,
        "filleted box volume should be ≈975.6 (in 974..978), got {vol}"
    );
}

#[test]
fn vertex_blend_tessellates_successfully() {
    // Verify the fully-filleted box can be tessellated without error.
    // Watertight stitching at NURBS-to-planar seams is a tessellation-level
    // concern tracked separately.
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);
    let edges = solid_edge_ids(&topo, cube);

    let result =
        fillet_rolling_ball(&mut topo, cube, &edges, 0.1).expect("all-edges fillet should succeed");

    let mesh = crate::tessellate::tessellate_solid(&topo, result, 0.05).unwrap();
    // Should produce a non-trivial mesh.
    assert!(mesh.positions.len() > 20, "should have many vertices");
    assert!(mesh.indices.len() > 60, "should have many triangles");
}

#[test]
fn vertex_blend_positive_volume() {
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);
    let edges = solid_edge_ids(&topo, cube);

    let result =
        fillet_rolling_ball(&mut topo, cube, &edges, 0.1).expect("all-edges fillet should succeed");

    let vol = crate::measure::solid_volume(&topo, result, 0.005).unwrap();
    // Analytic rounded-cube volume for s=1, r=0.1 (Minkowski sum of the inner
    // (s−2r)³ box with a ball of radius r):
    //   (0.8)³ + 6·(0.8)²·0.1 + 12·0.8·(π/4)·0.1² + (4/3)π·0.1³ ≈ 0.9756.
    assert!(
        vol > 0.970 && vol < 0.980,
        "filleted unit-cube volume should be ≈0.9756 (in 0.970..0.980), got {vol}"
    );
}

#[test]
fn vertex_blend_box_primitive() {
    // Test with make_box (2×3×4) to verify non-unit dimensions work.
    let mut topo = Topology::new();
    let solid = crate::primitives::make_box(&mut topo, 2.0, 3.0, 4.0).unwrap();
    let edges = solid_edge_ids(&topo, solid);
    assert_eq!(edges.len(), 12);

    let result = fillet_rolling_ball(&mut topo, solid, &edges, 0.2)
        .expect("box primitive all-edges fillet should succeed");

    let s = topo.solid(result).expect("result solid");
    let sh = topo.shell(s.outer_shell()).expect("shell");
    assert_eq!(sh.faces().len(), 26);
}

#[test]
fn vertex_blend_three_edges_at_corner() {
    // Fillet just the 3 edges meeting at one corner vertex to test minimal
    // vertex blend (produces one blend triangle).
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);
    let all_edges = solid_edge_ids(&topo, cube);

    // Find 3 edges sharing a common vertex.
    let mut vertex_to_edges: HashMap<usize, Vec<EdgeId>> = HashMap::new();
    for &eid in &all_edges {
        let e = topo.edge(eid).unwrap();
        vertex_to_edges
            .entry(e.start().index())
            .or_default()
            .push(eid);
        vertex_to_edges
            .entry(e.end().index())
            .or_default()
            .push(eid);
    }

    let (&_vi, corner_edges) = vertex_to_edges
        .iter()
        .find(|(_, edges)| edges.len() >= 3)
        .expect("box should have vertices with 3 edges");

    let targets: Vec<EdgeId> = corner_edges.iter().take(3).copied().collect();

    let result = fillet_rolling_ball(&mut topo, cube, &targets, 0.1)
        .expect("3-edge corner fillet should succeed");

    let s = topo.solid(result).expect("result solid");
    let sh = topo.shell(s.outer_shell()).expect("shell");

    // 6 original faces + 3 NURBS fillets + at least 1 vertex blend triangle
    assert!(
        sh.faces().len() >= 10,
        "expected at least 10 faces (6 + 3 + 1 blend), got {}",
        sh.faces().len()
    );
}

#[test]
fn vertex_blend_is_curved_not_flat() {
    // Fillet all 12 edges of a unit cube. Verify that vertex blend
    // NURBS patches approximate a spherical cap on the correct
    // fillet sphere: center at (corner - R*(1,1,1)/|...|), radius R.
    let r = 0.1_f64;
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);
    let edges = solid_edge_ids(&topo, cube);

    let result =
        fillet_rolling_ball(&mut topo, cube, &edges, r).expect("all-edges fillet should succeed");

    let solid = topo.solid(result).unwrap();
    let shell = topo.shell(solid.outer_shell()).unwrap();

    // For each blend face, check that interior surface points lie
    // approximately on a sphere of radius R centered inside the solid.
    let mut blend_face_count = 0;
    let mut max_sphere_err = 0.0_f64;

    for &fid in shell.faces() {
        let face = topo.face(fid).unwrap();
        if !matches!(face.surface(), FaceSurface::Nurbs(_)) {
            continue;
        }
        let wire = topo.wire(face.outer_wire()).unwrap();
        let wire_verts: Vec<Point3> = wire
            .edges()
            .iter()
            .map(|oe| {
                let v = topo.vertex(topo.edge(oe.edge()).unwrap().start()).unwrap();
                v.point()
            })
            .collect();
        if wire_verts.len() != 3 {
            continue;
        }
        blend_face_count += 1;

        // The sphere center is at the original cube corner offset
        // inward by R along each face normal. For a 90° corner with
        // axis-aligned face normals, this is corner ± R on each axis.
        // Find the nearest cube corner by rounding each boundary vertex
        // coordinate to 0 or 1.
        let avg = Point3::new(
            (wire_verts[0].x() + wire_verts[1].x() + wire_verts[2].x()) / 3.0,
            (wire_verts[0].y() + wire_verts[1].y() + wire_verts[2].y()) / 3.0,
            (wire_verts[0].z() + wire_verts[1].z() + wire_verts[2].z()) / 3.0,
        );
        let corner = Point3::new(
            if avg.x() > 0.5 { 1.0 } else { 0.0 },
            if avg.y() > 0.5 { 1.0 } else { 0.0 },
            if avg.z() > 0.5 { 1.0 } else { 0.0 },
        );
        let sphere_center = Point3::new(
            corner.x() + if corner.x() > 0.5 { -r } else { r },
            corner.y() + if corner.y() > 0.5 { -r } else { r },
            corner.z() + if corner.z() > 0.5 { -r } else { r },
        );

        // The boundary points are at distance √2·R from the sphere center
        // (they're on face planes, not on the fillet sphere itself).
        // The rational Bézier patch should lie on a sphere of that radius.
        let r_blend = (wire_verts[0] - sphere_center).length();

        // Evaluate interior points and check distance from sphere.
        if let FaceSurface::Nurbs(srf) = face.surface() {
            for u in [0.25, 0.5, 0.75] {
                for v in [0.25, 0.5, 0.75] {
                    let pt = srf.evaluate(u, v);
                    let dist = (pt - sphere_center).length();
                    let err = (dist - r_blend).abs();
                    max_sphere_err = max_sphere_err.max(err);
                }
            }
        }
    }

    assert!(
        blend_face_count >= 8,
        "expected 8 vertex blend faces, found {blend_face_count}"
    );
    // A degree (2,2) rational patch can't exactly represent a sphere —
    // the triangular degenerate topology introduces approximation error.
    // Allow up to 6% of the fillet radius (increased from 5% after fillet
    // contact direction fix which slightly shifts vertex blend sampling).
    assert!(
        max_sphere_err < r * 0.06,
        "blend surface deviates from sphere by {max_sphere_err:.6} (limit {:.6})",
        r * 0.06,
    );
}

#[test]
fn vertex_blend_sphere_center_inside_solid() {
    // Verify the blend surface midpoints are close to the solid
    // boundary. The (2,2) rational patch is an approximation of the
    // spherical cap, so allow up to R/2 overshoot past face planes.
    let r = 0.1_f64;
    let margin = r;
    let mut topo = Topology::new();
    let cube = make_unit_cube_manifold(&mut topo);
    let edges = solid_edge_ids(&topo, cube);

    let result =
        fillet_rolling_ball(&mut topo, cube, &edges, r).expect("all-edges fillet should succeed");

    let solid = topo.solid(result).unwrap();
    let shell = topo.shell(solid.outer_shell()).unwrap();

    for &fid in shell.faces() {
        let face = topo.face(fid).unwrap();
        if let FaceSurface::Nurbs(srf) = face.surface() {
            let wire = topo.wire(face.outer_wire()).unwrap();
            if wire.edges().len() != 3 {
                continue;
            }

            // Sample interior surface points — they should be
            // within the unit cube bounds (with some tolerance for
            // the quadratic patch approximation error).
            for u in [0.25, 0.5, 0.75] {
                for v in [0.25, 0.5] {
                    let pt = srf.evaluate(u, v);
                    assert!(
                        pt.x() > -margin
                            && pt.x() < 1.0 + margin
                            && pt.y() > -margin
                            && pt.y() < 1.0 + margin
                            && pt.z() > -margin
                            && pt.z() < 1.0 + margin,
                        "blend point ({:.4},{:.4},{:.4}) too far outside unit cube",
                        pt.x(),
                        pt.y(),
                        pt.z(),
                    );
                }
            }
        }
    }
}

/// Fillet on a boolean result: fuse(box, cylinder) → fillet should work
/// on edges shared between two planar faces.
#[test]
fn fillet_on_boolean_result() {
    let mut topo = Topology::new();
    let base = crate::primitives::make_box(&mut topo, 80.0, 60.0, 10.0).unwrap();
    let boss = crate::primitives::make_cylinder(&mut topo, 15.0, 30.0).unwrap();
    let mat = brepkit_math::mat::Mat4::translation(40.0, 30.0, 10.0);
    crate::transform::transform_solid(&mut topo, boss, &mat).unwrap();

    let fused =
        crate::boolean::boolean(&mut topo, crate::boolean::BooleanOp::Fuse, base, boss).unwrap();

    let solid = topo.solid(fused).unwrap();
    let shell = topo.shell(solid.outer_shell()).unwrap();

    // Build edge-to-face map from all wires (outer + inner).
    let mut edge_to_face_ids: HashMap<usize, Vec<FaceId>> = HashMap::new();
    for &fid in shell.faces() {
        let face = topo.face(fid).unwrap();
        let wire = topo.wire(face.outer_wire()).unwrap();
        for oe in wire.edges() {
            edge_to_face_ids
                .entry(oe.edge().index())
                .or_default()
                .push(fid);
        }
        for &iwid in face.inner_wires() {
            let iw = topo.wire(iwid).unwrap();
            for oe in iw.edges() {
                edge_to_face_ids
                    .entry(oe.edge().index())
                    .or_default()
                    .push(fid);
            }
        }
    }

    // Allow a small number of seam edges from cylindrical band discretization.
    let bad_count = edge_to_face_ids.values().filter(|f| f.len() != 2).count();
    assert!(
        bad_count <= 4,
        "too many non-manifold edges: {bad_count} (expected <= 4 seam edges)",
    );

    // Fillet only manifold edges where BOTH adjacent faces are planar.
    let is_planar = |fid: FaceId| -> bool {
        matches!(topo.face(fid).unwrap().surface(), FaceSurface::Plane { .. })
    };
    let mut planar_edges = Vec::new();
    for (&eidx, face_ids) in &edge_to_face_ids {
        if face_ids.len() == 2 && is_planar(face_ids[0]) && is_planar(face_ids[1]) {
            let face = topo.face(face_ids[0]).unwrap();
            let wire = topo.wire(face.outer_wire()).unwrap();
            for oe in wire.edges() {
                if oe.edge().index() == eidx {
                    planar_edges.push(oe.edge());
                    break;
                }
            }
        }
    }
    planar_edges.sort_unstable_by_key(|e| e.index());
    planar_edges.dedup_by_key(|e| e.index());

    assert!(
        !planar_edges.is_empty(),
        "should have planar-planar edges to fillet"
    );
    let result = fillet(&mut topo, fused, &planar_edges, 1.0);
    assert!(
        result.is_ok(),
        "fillet on planar edges of boolean result should succeed: {:?}",
        result.err()
    );
}

#[test]
fn fillet_radius_too_large_rejected() {
    let mut topo = Topology::new();
    let solid = crate::primitives::make_box(&mut topo, 2.0, 2.0, 2.0).unwrap();
    let edges = solid_edge_ids(&topo, solid);
    // Unit cube has edge length 2.0 — a radius of 3.0 exceeds adjacent edges.
    let result = fillet_rolling_ball(&mut topo, solid, &edges[..1], 3.0);
    assert!(result.is_err(), "should reject radius exceeding face size");
    let msg = format!("{}", result.unwrap_err());
    assert!(
        msg.contains("exceeds"),
        "error should mention exceeds: {msg}"
    );
}

#[test]
fn fillet_radius_exceeds_cylinder_curvature_rejected() {
    // A cylinder of radius 1.0 cannot be filleted with radius >= 1.0:
    // the offset surface would degenerate to a line.
    let mut topo = Topology::new();
    let solid = crate::primitives::make_cylinder(&mut topo, 1.0, 4.0).unwrap();
    let plane_cyl_edge = {
        let s = topo.solid(solid).unwrap();
        let sh = topo.shell(s.outer_shell()).unwrap();
        let mut edge_faces: HashMap<usize, Vec<FaceId>> = HashMap::new();
        for &fid in sh.faces() {
            let wire = topo.wire(topo.face(fid).unwrap().outer_wire()).unwrap();
            for oe in wire.edges() {
                edge_faces.entry(oe.edge().index()).or_default().push(fid);
            }
        }
        let mut found = None;
        'outer: for (&eidx, fids) in &edge_faces {
            if fids.len() == 2 {
                let s1 = topo.face(fids[0]).unwrap().surface().clone();
                let s2 = topo.face(fids[1]).unwrap().surface().clone();
                let has_plane = matches!(s1, FaceSurface::Plane { .. })
                    || matches!(s2, FaceSurface::Plane { .. });
                let has_cyl = matches!(s1, FaceSurface::Cylinder(_))
                    || matches!(s2, FaceSurface::Cylinder(_));
                if has_plane && has_cyl {
                    for &fid in sh.faces() {
                        let wire = topo.wire(topo.face(fid).unwrap().outer_wire()).unwrap();
                        for oe in wire.edges() {
                            if oe.edge().index() == eidx {
                                found = Some(oe.edge());
                                break 'outer;
                            }
                        }
                    }
                }
            }
        }
        found.expect("cylinder must have a plane-cylinder edge")
    };

    // radius == cylinder radius → curvature radius exactly met → reject.
    let result = fillet_rolling_ball(&mut topo, solid, &[plane_cyl_edge], 1.0);
    assert!(
        result.is_err(),
        "radius == cylinder radius should be rejected"
    );
    let msg = format!("{}", result.unwrap_err());
    assert!(
        msg.contains("curvature"),
        "error should mention curvature: {msg}"
    );

    // radius > cylinder radius → also rejected.
    let result2 = fillet_rolling_ball(&mut topo, solid, &[plane_cyl_edge], 1.5);
    assert!(
        result2.is_err(),
        "radius > cylinder radius should be rejected"
    );

    // radius < cylinder radius → passes curvature check (may succeed or fail
    // for other fillet reasons, but must not fail on curvature).
    let result3 = fillet_rolling_ball(&mut topo, solid, &[plane_cyl_edge], 0.3);
    if let Err(ref e) = result3 {
        let msg = format!("{e}");
        assert!(
            !msg.contains("curvature"),
            "small radius should not fail curvature check: {msg}"
        );
    }
}

#[test]
fn fillet_radius_just_fits() {
    let mut topo = Topology::new();
    let solid = crate::primitives::make_box(&mut topo, 4.0, 4.0, 4.0).unwrap();
    let edges = solid_edge_ids(&topo, solid);
    // Edge length is 4.0 — a radius of 1.0 should fit comfortably.
    let result = fillet_rolling_ball(&mut topo, solid, &edges[..1], 1.0);
    assert!(
        result.is_ok(),
        "small radius should succeed: {:?}",
        result.err()
    );
}

#[test]
fn fillet_plane_cylinder_edge() {
    // A cylinder's rim edges are CLOSED circles (start vertex == end vertex).
    // The rolling-ball engine is built around polygonal wires with distinct
    // corner vertices; a closed circular edge collapses its blend strip and the
    // adjacent disc cap to zero-area faces (the result is manifold but
    // geometrically degenerate — it silently drops the caps and shrinks the
    // wall, removing ~35% of the volume; see gh #967). The engine must reject
    // this rather than return the broken solid, so the dispatcher
    // (`wasm::try_fillet`) falls through to the walking blend engine
    // (`blend_ops::fillet_v2`), which rounds a closed rim correctly.
    let mut topo = Topology::new();
    let solid = crate::primitives::make_cylinder(&mut topo, 2.0, 4.0).unwrap();

    // Find edges that border both a planar face and a cylindrical face.
    let s = topo.solid(solid).unwrap();
    let sh = topo.shell(s.outer_shell()).unwrap();
    let mut plane_cyl_edges: Vec<EdgeId> = Vec::new();
    let mut edge_faces: HashMap<usize, Vec<FaceId>> = HashMap::new();

    for &fid in sh.faces() {
        let face = topo.face(fid).unwrap();
        let wire = topo.wire(face.outer_wire()).unwrap();
        for oe in wire.edges() {
            edge_faces.entry(oe.edge().index()).or_default().push(fid);
        }
    }

    for (&eidx, fids) in &edge_faces {
        if fids.len() == 2 {
            let s1 = topo.face(fids[0]).unwrap().surface().clone();
            let s2 = topo.face(fids[1]).unwrap().surface().clone();
            let has_plane =
                matches!(s1, FaceSurface::Plane { .. }) || matches!(s2, FaceSurface::Plane { .. });
            let has_cyl =
                matches!(s1, FaceSurface::Cylinder(_)) || matches!(s2, FaceSurface::Cylinder(_));
            if has_plane && has_cyl {
                // Recover the EdgeId from eidx — walk the shell to find it.
                for &fid in sh.faces() {
                    let face = topo.face(fid).unwrap();
                    let wire = topo.wire(face.outer_wire()).unwrap();
                    for oe in wire.edges() {
                        if oe.edge().index() == eidx {
                            plane_cyl_edges.push(oe.edge());
                        }
                    }
                }
                break; // Just need one edge for the test
            }
        }
    }

    assert!(
        !plane_cyl_edges.is_empty(),
        "cylinder should have plane-cylinder edges"
    );

    // Filleting the closed rim circle must be REJECTED (not return a degenerate
    // solid). The rejection lets the dispatcher fall through to the walking
    // engine, which rounds the rim into an exact quarter-torus (gh #967).
    let result = fillet_rolling_ball(&mut topo, solid, &plane_cyl_edges[..1], 0.3);
    assert!(
        result.is_err(),
        "rolling-ball fillet of a closed cylinder-rim edge must be rejected as \
         degenerate, not return a silently-broken solid"
    );
    let msg = format!("{}", result.err().unwrap());
    assert!(
        msg.contains("degenerate"),
        "expected a degenerate-face rejection, got: {msg}"
    );
}

#[test]
fn g1_propagate_box_no_expansion() {
    // On a box every edge meets its neighbors at 90°.
    // Seeding one edge should yield a set of size exactly 1 — no expansion.
    let mut topo = Topology::new();
    let solid = crate::primitives::make_box(&mut topo, 1.0, 1.0, 1.0).unwrap();
    let edges = solid_edge_ids(&topo, solid);
    let seed = &edges[..1];

    // expand_g1_chain is private; exercise it via the public wrapper.
    // We expect the wrapper to succeed and the fillet result to be valid
    // (same as seeding with the single edge directly).
    let result = fillet_rolling_ball_propagate_g1(&mut topo, solid, seed, 0.1);
    assert!(
        result.is_ok(),
        "propagate_g1 on a box edge should succeed: {:?}",
        result.err()
    );
    let result_solid = result.unwrap();
    let vol = crate::measure::solid_volume(&topo, result_solid, 0.01).unwrap();
    assert!(
        vol > 0.0 && vol < 1.0,
        "filleted box should have smaller volume than original: {vol}"
    );
}

#[test]
fn g1_propagate_collinear_long_box() {
    // Build a long box (4×1×1) and seed one of the long top edges.
    // A box's long edges are each a single edge, so propagation still
    // yields size 1 — but the wrapper should succeed and produce a valid solid.
    let mut topo = Topology::new();
    let solid = crate::primitives::make_box(&mut topo, 4.0, 1.0, 1.0).unwrap();

    // Pick the first edge that is parallel to the X axis (length ≈ 4.0).
    let edges = solid_edge_ids(&topo, solid);
    let long_edge = edges
        .iter()
        .find(|&&eid| {
            let e = topo.edge(eid).unwrap();
            let p0 = topo.vertex(e.start()).unwrap().point();
            let p1 = topo.vertex(e.end()).unwrap().point();
            let len = (p1 - p0).length();
            len > 3.5
        })
        .copied();
    let seed_edge = long_edge.expect("could not find a long edge on a 4×1×1 box");

    let result = fillet_rolling_ball_propagate_g1(&mut topo, solid, &[seed_edge], 0.1);
    assert!(
        result.is_ok(),
        "propagate_g1 on long-box edge should succeed: {:?}",
        result.err()
    );
    let result_solid = result.unwrap();
    let vol = crate::measure::solid_volume(&topo, result_solid, 0.01).unwrap();
    assert!(
        vol > 0.0 && vol < 4.0,
        "filleted long box volume should be positive and less than original: {vol}"
    );
}

#[test]
fn adjacent_fillet_overlap_all_edges_rejected() {
    // A 1×1×1 box with all 12 edges filleted at R=0.5 must fail:
    // at each 90° corner the setback from each end is R/tan(45°) = 0.5,
    // and 0.5 + 0.5 = 1.0 = edge length → strips exactly touch → reject.
    let mut topo = Topology::new();
    let solid = crate::primitives::make_box(&mut topo, 1.0, 1.0, 1.0).unwrap();
    let edges = solid_edge_ids(&topo, solid);
    let result = fillet_rolling_ball(&mut topo, solid, &edges, 0.5);
    assert!(
        result.is_err(),
        "all-edge fillet with R=0.5 on unit box should be rejected"
    );
    let msg = format!("{}", result.unwrap_err());
    assert!(
        msg.contains("adjacent fillet strips overlap"),
        "error should mention overlap: {msg}"
    );
}

#[test]
fn adjacent_fillet_overlap_fits_with_small_radius() {
    // The same box with R=0.4 must succeed: 0.4+0.4=0.8 < 1.0.
    // (We don't check the full solid validity here — that's covered by
    // vertex_blend_all_edges_box.  Just verify Phase 2d does not block it.)
    let mut topo = Topology::new();
    let solid = crate::primitives::make_box(&mut topo, 1.0, 1.0, 1.0).unwrap();
    let edges = solid_edge_ids(&topo, solid);
    let result = fillet_rolling_ball(&mut topo, solid, &edges, 0.4);
    assert!(
        result.is_ok(),
        "all-edge fillet with R=0.4 on unit box should be accepted by Phase 2d: {:?}",
        result.err()
    );
}

#[test]
fn adjacent_fillet_single_edge_no_phase2d_rejection() {
    // Filleting one edge of a box has no adjacent target edges — Phase 2d
    // never fires even for R close to the face size.
    let mut topo = Topology::new();
    let solid = crate::primitives::make_box(&mut topo, 1.0, 1.0, 1.0).unwrap();
    let edges = solid_edge_ids(&topo, solid);
    // Phase 2b caps R at the adjacent edge length (1.0). R=0.4 is well below that.
    let result = fillet_rolling_ball(&mut topo, solid, &edges[..1], 0.4);
    assert!(
        result.is_ok(),
        "single-edge fillet with R=0.4 should succeed: {:?}",
        result.err()
    );
}

#[test]
fn face_surface_normal_at_nurbs_via_projection() {
    // Directly test the NURBS branch of face_surface_normal_at.
    // Build a flat bilinear NURBS patch in the XY plane.  The outward
    // normal is (0, 0, 1) everywhere; point projection must return a
    // valid (u, v) that yields the correct normal.
    let srf = NurbsSurface::new(
        1,
        1,
        vec![0.0, 0.0, 1.0, 1.0],
        vec![0.0, 0.0, 1.0, 1.0],
        vec![
            vec![Point3::new(0.0, 0.0, 0.0), Point3::new(0.0, 1.0, 0.0)],
            vec![Point3::new(1.0, 0.0, 0.0), Point3::new(1.0, 1.0, 0.0)],
        ],
        vec![vec![1.0, 1.0], vec![1.0, 1.0]],
    )
    .expect("bilinear XY patch");

    let surface = FaceSurface::Nurbs(srf);

    // Test at a non-central point to ensure projection (not midpoint) is used.
    let n = face_surface_normal_at(&surface, Point3::new(0.2, 0.8, 0.0));
    let n = n.expect("NURBS normal should be Some for a surface point");

    // Flat XY patch has normal along ±Z.
    assert!(
        n.z().abs() > 0.9,
        "flat XY patch normal must be along Z, got: {n:?}"
    );
    // Result must be approximately unit length.
    assert!(
        (n.length() - 1.0).abs() < 0.01,
        "NURBS normal must be unit length, got: {}",
        n.length()
    );
}

#[test]
fn fillet_rolling_ball_second_pass_on_nurbs_solid() {
    // After a rolling-ball fillet the result solid contains a NURBS face.
    // A second fillet on a different manifold edge must succeed.  This
    // verifies that face_surfaces containing NURBS entries does not crash
    // fillet_rolling_ball even when the NURBS face is non-manifold in the
    // current implementation (so its normal branch is not reached yet).
    let mut topo = Topology::new();
    let solid = make_unit_cube_manifold(&mut topo);

    let edges1 = solid_edge_ids(&topo, solid);
    let result1 = fillet_rolling_ball(&mut topo, solid, &[edges1[0]], 0.1)
        .expect("first rolling-ball fillet should succeed");

    // Confirm a blend face was created (a cylinder here, NURBS for curved
    // neighbours).
    let has_nurbs = {
        let s = topo.solid(result1).unwrap();
        let sh = topo.shell(s.outer_shell()).unwrap();
        sh.faces()
            .iter()
            .any(|&fid| !topo.face(fid).unwrap().surface().is_planar())
    };
    assert!(has_nurbs, "first fillet must produce a blend face");

    // Second fillet on a different edge.
    let edges2 = solid_edge_ids(&topo, result1);
    let result2 = fillet_rolling_ball(&mut topo, result1, &[edges2[1]], 0.05);
    assert!(
        result2.is_ok(),
        "second fillet on NURBS-containing solid must succeed: {:?}",
        result2.err()
    );

    let vol = crate::measure::solid_volume(&topo, result2.unwrap(), 0.1).unwrap();
    assert!(
        vol > 0.5,
        "doubly-filleted solid must have positive volume, got {vol}"
    );
}

#[test]
fn fillet_on_fillet_box() {
    // Fillet all 12 edges of a box, then fillet the resulting NURBS edges.
    let mut topo = Topology::new();
    let solid = crate::primitives::make_box(&mut topo, 2.0, 2.0, 2.0).unwrap();
    let edges = solid_edge_ids(&topo, solid);

    let result1 = fillet_rolling_ball(&mut topo, solid, &edges, 0.1).unwrap();
    let vol1 = crate::measure::solid_volume(&topo, result1, 0.01).unwrap();
    assert!(vol1 > 0.0, "first fillet should produce positive volume");

    let edges2 = solid_edge_ids(&topo, result1);
    assert!(
        !edges2.is_empty(),
        "filleted solid must have edges for second fillet attempt"
    );

    // Try to fillet one of the new NURBS-NURBS edges with smaller radius.
    // This should not panic or error — it's the #39 test.
    let result2 = fillet_rolling_ball(&mut topo, result1, &edges2[..1], 0.05);
    match result2 {
        Ok(solid2) => {
            let vol2 = crate::measure::solid_volume(&topo, solid2, 0.01).unwrap();
            assert!(vol2 > 0.0, "second fillet should produce positive volume");
        }
        Err(e) => {
            // Graceful failure is acceptable — log the error for diagnostics
            eprintln!("second fillet failed gracefully: {e}");
        }
    }
}

#[test]
fn adjacent_fillet_overlap_curved_face_detected() {
    // Two small fillets on a cylinder face that would overlap.
    let mut topo = Topology::new();
    let cyl = crate::primitives::make_cylinder(&mut topo, 1.0, 2.0).unwrap();

    // Get edges - the cylinder has circle edges at top and bottom
    let edges = solid_edge_ids(&topo, cyl);

    // Try to fillet with a very large radius that should trigger overlap
    // on the curved cylinder face
    let result = fillet_rolling_ball(&mut topo, cyl, &edges, 0.9);
    // Should either succeed (if no overlap) or return an error (if overlap detected)
    // The key is: it should NOT panic
    match result {
        Ok(solid) => {
            let vol = crate::measure::solid_volume(&topo, solid, 0.01).unwrap();
            assert!(vol > 0.0);
        }
        Err(e) => {
            // A large radius on the closed cylinder rim is expected to fail.
            // Acceptable reasons: overlap / curvature bound, or the degenerate
            // closed-circular-edge rejection (the rim collapses the blend strip;
            // see gh #967). The key is that it must NOT panic.
            let msg = format!("{e}");
            assert!(
                msg.contains("overlap")
                    || msg.contains("curvature")
                    || msg.contains("exceeds")
                    || msg.contains("degenerate"),
                "expected overlap/curvature/degenerate error, got: {msg}"
            );
        }
    }
}

#[test]
fn g1_chain_no_expansion_for_box() {
    // Box edges meet at 90 degrees — no G1 chains should be detected.
    // Filleting a single edge should succeed without expanding.
    let mut topo = Topology::new();
    let solid = crate::primitives::make_box(&mut topo, 2.0, 2.0, 2.0).unwrap();
    let edges = solid_edge_ids(&topo, solid);

    // Fillet a single edge with a small radius.
    let result = fillet_rolling_ball(&mut topo, solid, &edges[..1], 0.1);
    assert!(
        result.is_ok(),
        "single-edge fillet on box should succeed: {:?}",
        result.err()
    );

    let result_solid = result.unwrap();
    let vol = crate::measure::solid_volume(&topo, result_solid, 0.01).unwrap();
    // Original box volume: 8.0; fillet removes a small amount.
    assert!(
        vol > 7.0 && vol < 8.0,
        "filleted box volume should be slightly less than 8.0, got {vol}"
    );
}

#[test]
fn g1_chain_integrated_matches_explicit_wrapper() {
    // Since fillet_rolling_ball now does G1 expansion internally,
    // calling it directly on a seed should give the same result as
    // the explicit propagate_g1 wrapper.
    let mut topo1 = Topology::new();
    let solid1 = crate::primitives::make_box(&mut topo1, 1.0, 1.0, 1.0).unwrap();
    let edges1 = solid_edge_ids(&topo1, solid1);
    let result1 = fillet_rolling_ball(&mut topo1, solid1, &edges1[..1], 0.1);
    assert!(result1.is_ok(), "direct call should succeed");
    let vol1 = crate::measure::solid_volume(&topo1, result1.unwrap(), 0.01).unwrap();

    let mut topo2 = Topology::new();
    let solid2 = crate::primitives::make_box(&mut topo2, 1.0, 1.0, 1.0).unwrap();
    let edges2 = solid_edge_ids(&topo2, solid2);
    let result2 = fillet_rolling_ball_propagate_g1(&mut topo2, solid2, &edges2[..1], 0.1);
    assert!(result2.is_ok(), "wrapper call should succeed");
    let vol2 = crate::measure::solid_volume(&topo2, result2.unwrap(), 0.01).unwrap();

    // Both should produce the same volume (within tolerance).
    assert!(
        (vol1 - vol2).abs() < 0.01,
        "volumes should match: direct={vol1}, wrapper={vol2}"
    );
}

/// Dihedral angle (degrees) between the two faces of an edge, sampled at the
/// edge midpoint, using effective (reversal-adjusted) outward normals.
fn dihedral_deg(topo: &Topology, e: EdgeId, fs: &[FaceId]) -> f64 {
    let ed = topo.edge(e).unwrap();
    let a = topo.vertex(ed.start()).unwrap().point();
    let b = topo.vertex(ed.end()).unwrap().point();
    let mid = a + (b - a) * 0.5;
    let nrm = |fid: FaceId| {
        let face = topo.face(fid).unwrap();
        let n = match face.surface() {
            FaceSurface::Plane { normal, .. } => *normal,
            other => {
                let (u, v) = other.project_point(mid).unwrap_or((0.0, 0.0));
                other.normal(u, v)
            }
        };
        let n = if face.is_reversed() { -n } else { n };
        n.normalize().unwrap()
    };
    nrm(fs[0])
        .dot(nrm(fs[1]))
        .clamp(-1.0, 1.0)
        .acos()
        .to_degrees()
}

/// #834: round an edge whose neighbour is a previous fillet's NURBS blend face.
///
/// A single-edge rolling-ball fillet yields a watertight solid with a NURBS
/// blend face. Filleting a (non-tangent) edge bordering that blend face must
/// itself produce a valid, watertight manifold — the blend's accessible
/// non-degenerate edges are concave end-caps, so the fillet fills the seam.
#[test]
fn fillet_edge_adjacent_to_nurbs_blend_is_watertight() {
    use brepkit_topology::validation::validate_shell_closed;

    let mut topo = Topology::new();
    let cube = crate::primitives::make_box(&mut topo, 10.0, 10.0, 10.0).unwrap();
    let edges = solid_edge_ids(&topo, cube);

    // First fillet — one box edge → a watertight solid with a NURBS blend face.
    let first = fillet_rolling_ball(&mut topo, cube, &[edges[0]], 1.0).unwrap();
    {
        let sh = topo
            .shell(topo.solid(first).unwrap().outer_shell())
            .unwrap();
        validate_shell_closed(sh, &topo).expect("first fillet should be watertight");
    }
    let vol1 = crate::measure::solid_volume(&topo, first, 0.05).unwrap();

    // Collect NURBS blend faces and edge→faces adjacency.
    let blend_faces: HashSet<usize> = {
        let sh = topo
            .shell(topo.solid(first).unwrap().outer_shell())
            .unwrap();
        sh.faces()
            .iter()
            .filter(|&&f| !topo.face(f).unwrap().surface().is_planar())
            .map(|f| f.index())
            .collect()
    };
    assert!(
        !blend_faces.is_empty(),
        "first fillet must create a blend face"
    );

    let mut ef: HashMap<usize, Vec<FaceId>> = HashMap::new();
    {
        let sh = topo
            .shell(topo.solid(first).unwrap().outer_shell())
            .unwrap();
        for &fid in sh.faces() {
            for oe in topo
                .wire(topo.face(fid).unwrap().outer_wire())
                .unwrap()
                .edges()
            {
                ef.entry(oe.edge().index()).or_default().push(fid);
            }
        }
    }

    // A non-tangent edge bordering the NURBS blend face (the tangent contact
    // lines are G1/degenerate and are not fillettable).
    let target = solid_edge_ids(&topo, first)
        .into_iter()
        .find(|&e| {
            ef.get(&e.index()).is_some_and(|fs| {
                fs.len() == 2
                    && fs.iter().any(|f| blend_faces.contains(&f.index()))
                    && dihedral_deg(&topo, e, fs) > 5.0
            })
        })
        .expect("a non-tangent edge bordering the NURBS blend face");

    // Second fillet on that NURBS-blend-adjacent edge.
    let result = fillet_rolling_ball(&mut topo, first, &[target], 0.5).unwrap();
    let sh = topo
        .shell(topo.solid(result).unwrap().outer_shell())
        .unwrap();
    validate_shell_manifold(sh, &topo).expect("second fillet must be manifold");
    validate_shell_closed(sh, &topo)
        .expect("second fillet on a NURBS-blend-adjacent edge must be watertight");

    let vol2 = crate::measure::solid_volume(&topo, result, 0.05).unwrap();
    // Concave end-cap edge → the fillet fills; volume stays sane (between the
    // first fillet and the original box).
    assert!(
        vol2 > vol1 - 1e-6 && vol2 <= 1000.0 + 1e-6,
        "filled fillet volume out of range: first={vol1}, second={vol2}"
    );
}