Rework of copper pour logic v2 (only kicad and fusion/eagle)

RicardoJCMarques · RicardoJCMarques · commit 97ecc8a3bb02 · 2026-03-14T01:55:57.000Z
diff --git a/CHANGELOG.md b/CHANGELOG.md
@@ -4,10 +4,16 @@ All notable changes to the **EasyTrace5000** project will be documented in this
 
 The format is based on [Keep a Changelog](https://keepachangelog.com/en/1.1.0/), and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0.html).
 
+## [1.0.10] - 2026-XX-XX
+
+### Fixed
+- **Copper Pour Regions:** KiCAD and Fusion/Eagle copper pours should now interact correctly with all geometry. (EasyEDA pours TBD.)
+- **Minor Optimizations** 
+
 ## [1.0.9] - 2026-03-11
 
 ### Fixed
-- **Winding Enforcement:** Winding is now set at the source to avoid having to check and fixing everywhere else.
+- **Winding Enforcement:** Winding is now set at the source to avoid having to check and fix it everywhere else.
 - **Further Optimizations:** Removed useless winding checks and enforcements through-out.
 
 ### Changed
@@ -22,11 +28,11 @@ The format is based on [Keep a Changelog](https://keepachangelog.com/en/1.1.0/),
 - **Changes to the offset pipeline made everything slightly more accurate but slower, optimization to come**
 
 ### Added
-- **Arc Definitions in Laser SVGs:** Offset Strategy Arcs in exported Laser SVGs will come out right now.
+- **Copper Pour Regions:** KiCAD and Fusion Copper Pour regions are now correctly parsed, plotted and processed in Copper Isolation Operations (Copper Clear works but is even slower).
 - **New Tiny/Noisy/Collapsed Arc Safeguards:** More protections against small arcs with a tendency to collapse on themselfes, plus less random unnecessarily small arcs.
 
 ### Fixed
-- **Copper Pour Regions:** KiCAD and Fusion Copper Pour regions are now correctly parsed, plotted and processed in Copper Isolation Operations (Copper Clear works but is even slower).
+- **Arc Definitions in Laser SVGs:** Offset Strategy Arcs in exported Laser SVGs will come out right now.
 - **Clipper Wrapper and Arc Reconstruction Optimizations:** Older modules - newish logic.
 
 ### Changed
diff --git a/cam-controller.js b/cam-controller.js
@@ -260,7 +260,7 @@
                 this.machineProcessor = new MachineProcessor(this.core);                
 
                 // Initialize UI with core and language manager
-                this.ui = new PCBCamUI(this.core, this.languageManager)
+                this.ui = new PCBCamUI(this.core, this.languageManager);
 
                 // Initialize UI (pass parameter manager)
                 const uiReady = await this.ui.init(this.parameterManager);
diff --git a/cam-core.js b/cam-core.js
diff --git a/config.js b/config.js
@@ -37,7 +37,7 @@ window.PCBCAMConfig = {
             name: 'Isolation Routing',
             icon: '🎯',
             extensions: ['.gbr', '.ger', '.gtl', '.gbl', '.gts', '.gbs', '.svg'],
-            defaultTool: 'em_0.1mm_flat',  // Tool ID - diameter comes from tools.json
+            defaultTool: 'em_0.2mm_flat',  // Tool ID - diameter comes from tools.json
             cutting: {
                 cutDepth: -0.04,
                 passDepth: 0.04,
@@ -709,7 +709,7 @@ window.PCBCAMConfig = {
         // Per-operation defaults (merged into operations config)
         operationDefaults: {
             isolation: {
-                isolationWidth: 0.3, // mm — total copper removal width
+                isolationWidth: 0.4, // mm — total copper removal width
                 stepOver: 10, // %
                 clearStrategy: 'offset',
                 hatchAngle: 0
diff --git a/geometry/geometry-arc-reconstructor.js b/geometry/geometry-arc-reconstructor.js
diff --git a/geometry/geometry-offsetter.js b/geometry/geometry-offsetter.js
@@ -447,12 +447,12 @@
                         });
 
                         return new PathPrimitive([{
-                            points: offsetResult.points,
+                            points: offsetPoints,
                             isHole: contour.isHole || false,
-                            nestingLevel: 0,
-                            parentId: null,
-                            arcSegments: offsetResult.arcSegments,
-                            curveIds: offsetResult.curveIds
+                            nestingLevel: contour.nestingLevel || 0,
+                            parentId: contour.parentId || null,
+                            arcSegments: [],
+                            curveIds: collectedCurveIds
                         }], makeProps(contour.isHole ? 'clear' : 'dark'));
                     }
                 } catch (e) {
@@ -472,9 +472,9 @@
 
             return new PathPrimitive([{
                 points: offsetPoints,
-                isHole: false,
-                nestingLevel: 0,
-                parentId: null,
+                isHole: contour.isHole || false,
+                nestingLevel: contour.nestingLevel || 0,
+                parentId: contour.parentId || null,
                 arcSegments: [],
                 curveIds: collectedCurveIds
             }], {
@@ -546,14 +546,15 @@
             const offsetSegments = [];
             for (let i = 0; i < n; i++) {
                 const p1 = polygonPoints[i];
-                const p2 = polygonPoints[(i + 1) % n];
+                const p2 = polygonPoints[i === n - 1 ? 0 : i + 1]; // Optimized wrapping
 
-                const v = { x: p2.x - p1.x, y: p2.y - p1.y };
-                const len = Math.hypot(v.x, v.y);
+                const dx = p2.x - p1.x;
+                const dy = p2.y - p1.y;
+                const len = Math.sqrt(dx * dx + dy * dy); // ~4x faster than Math.hypot
                 if (len < this.options.precision) continue;
 
-                const nx = normalDirection * (-v.y / len);
-                const ny = normalDirection * (v.x / len);
+                const nx = normalDirection * (-dy / len);
+                const ny = normalDirection * (dx / len);
 
                 offsetSegments.push({
                     p1: { x: p1.x + nx * offsetDist, y: p1.y + ny * offsetDist },
diff --git a/geometry/geometry-utils.js b/geometry/geometry-utils.js
@@ -450,8 +450,9 @@
             if (!points || points.length < 3) return 0;
 
             let area = 0;
-            for (let i = 0; i < points.length; i++) {
-                const j = (i + 1) % points.length;
+            const len = points.length;
+            for (let i = 0; i < len; i++) {
+                const j = i === len - 1 ? 0 : i + 1; // 2-3x faster than modulo
                 area += points[i].x * points[j].y;
                 area -= points[j].x * points[i].y;
             }
@@ -587,8 +588,8 @@
             return boundaryStrokes;
         },
 
-         /**
-         * polylineToPolygon has been deprecated in favor of traceToPolygon that generates joint geometry that is easier to process.
+        /**
+        * polylineToPolygon has been deprecated in favor of traceToPolygon that generates joint geometry that is easier to process. They will remain until commented out until analytic offset path development is restarted.
         // Convert polyline to polygon with metadata for end-caps
         polylineToPolygon(points, width, curveIds = []) {
             if (!points || points.length < 2) return [];
@@ -677,7 +678,7 @@
          */
 
         /**
-         * Optimized: Converts a closed contour into overlapping stroke polygons.
+         * Converts a closed contour into overlapping stroke polygons.
          * Fixes spikes by merging micro-segments, while strictly protecting registered curve points.
          */
         closedContourToStrokePolygons(contour, strokeWidth) {
@@ -814,9 +815,10 @@
         },
 
         /**
+        * polylineToPolygon has been deprecated in favor of traceToPolygon that generates joint geometry that is easier to process. They will remain until commented out until analytic offset path development is restarted.
+        * lineToPolygon is only called by polylineToPolygon.
          * Converts a line to a polygon, returning a flat point array.
          * It registers end-caps and tags points with curveId.
-         */
         lineToPolygon(from, to, width, curveIds = []) {
             const dx = to.x - from.x;
             const dy = to.y - from.y;
@@ -950,6 +952,7 @@
             points.push({ x: to.x + nx, y: to.y + ny });
             return points;
         },
+         */
 
         /**
          * Converts an arc to a polygon, returning a structured object containing points, arcSegments, and curveIds.
diff --git a/toolpath/toolpath-optimizer.js b/toolpath/toolpath-optimizer.js
@@ -623,7 +623,9 @@
                 const cmd = plan.commands[i];
                 if (cmd.x === null || cmd.y === null) continue;
 
-                const dist = Math.hypot(cmd.x - fromPos.x, cmd.y - fromPos.y);
+                const dx = cmd.x - fromPos.x;
+                const dy = cmd.y - fromPos.y;
+                const dist = Math.sqrt(dx * dx + dy * dy); // ~4x faster than Math.hypot
 
                 if (dist < bestDist) {
                     bestDist = dist;
