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Add guards in rounded_corner_segment_line_arc and rounded_corner_line_arc for three degenerate cases that crash during CurvilinearPolygon rounding: 1. Fillet center coincides with arc center (norm(C_f - O) < atol), producing NaN from the direction vector division 2. Tangent points collapse onto fillet center (fillet_r < atol), producing NaN from zero-length direction vectors 3. Fillet sweep angle below min_angle, producing arcs too small for GMSH to distinguish from a line All three return nothing (skip rounding, leave corner sharp).
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gpeairs
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Apr 15, 2026
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This looks good, one small comment and a question about the TODO.
| # When the fillet sweep angle is tiny, the arc sagitta | ||
| # (r·(1 - cos(dα/2))) is sub-nanometer — GMSH can't distinguish it from | ||
| # a line and rejects it. Skip rounding this corner. | ||
| # TODO: instead of skipping, fall through to line-line rounding |
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Is this TODO needed? If I understand the geometry right, this should also be skipped for being below min_angle in line-line rounding (at least approximately).
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| catch e | ||
| # Arc too small or degenerate for GMSH — fall back to straight line. | ||
| # This typically happens with fillet arcs at nearly-tangent corners | ||
| # where the sagitta is below GMSH's internal tolerance. | ||
| @debug "addCircleArc failed, falling back to line" p0 = seg.p0 r = seg.r α = seg.α α0 = | ||
| seg.α0 | ||
| return k.add_line(endpoints[1], endpoints[2]) | ||
| end |
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I worry about hiding real changes to geometry under a @debug message. I'd suggest making sure it's not some other error:
catch e
if contains(string(e), <substring of expected error message text>)
@debug ...
return k.add_line(endpoints[1], endpoints[2])
end
rethrow()
end
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Add guards in
rounded_corner_segment_line_arcandrounded_corner_line_arcfor three degenerate cases that crash during CurvilinearPolygon rounding:All three return nothing (skip rounding, leave corner sharp).