calibration: torture test -- one part with ramps, ball, thin ledge, table, mushroom, cave, sideways holes and an arch, built in Full coverage at the defaults (must-hold 95 %); coupon.py label() for its raised angle / hole sizes

prototype/calibration/README.md

@@ -178,6 +178,21 @@ bore's axis, inside the bore, running out the open end; 0 unserved. Checks the
 2026-09-27 reversal (bores DO get supported) on a printed part.
 - **waiting on print.**
 
+### torture/ -- one part with every hard shape, as the site supports it (no setting)
+Not a rung coupon: a showcase that sets nothing. A spine on the plate with, front:
+40 / 30 / 20 deg ramps rising 10 mm (angle raised on top), a 20 mm ball, a 2 mm
+ledge 18 mm out and 24 mm up; back: a table (30 mm flat bridge, 14 up), a 26 mm
+mushroom cap on a 5 mm stem, a cave (18 x 14 flat ceiling); through the spine:
+3 / 6 / 12 mm sideways holes (size raised above each); on the end: an arch tunnel.
+One build in Full coverage (mode 'full') at every other default, all supports kept.
+Every feature is big enough for real walls (10-26 mm long), so the print shows
+whether each kind snaps off clean. A point-down tip in the first draft was dropped
+(Matthew: a mess, tells us nothing).
+- **2026-10-06 build:** 32 walls (10 from the fill pass), must-hold 95 % of 2977 mm2
+  (coverage scoreboard). Still bare: thin strips along the arch's curved sides and
+  the 12 mm hole's sides.
+- **waiting on print.**
+
 ### bite/ -- RETIRED 2026-10-03 (files removed; last in git at 6ec7c16)
 Asked how far tines should reach into the part (the old Tine bite field): twelve 40 deg
 ledges, bite 0.15-0.70. **Printed twice in PLA: every rung fused and left a mark, none

prototype/calibration/torture/build.js

@@ -0,0 +1,17 @@
+/**
+ * Torture test, step 2: ONE build of the whole part the way the site makes it --
+ * Full coverage (mode 'full') at every other default -- and every support kept.
+ * Prints what got walls and what Full coverage says no wall can reach.
+ *
+ *   deno run -A prototype/calibration/torture/build.js
+ */
+import { loadCoupon, finsWith, supportOf, writeCoupon } from '../coupon.js';
+
+const c = loadCoupon(import.meta.url);
+const built = finsWith(c, { mode: 'full' });
+const kinds = {};
+for (const f of built.fins) { const k = f.kind + (f.short ? ' (short)' : ''); kinds[k] = (kinds[k] ?? 0) + 1; }
+console.log('walls', kinds, 'fill walls', built.fill?.walls ?? built.fins.filter((f) => f.fill).length,
+  'tines', built.tines, 'pad', !!built.pad);
+console.log('fill', JSON.stringify(built.fill, (k, v) => (Array.isArray(v) && v.length > 8 ? `[${v.length}]` : v)));
+await writeCoupon(c, 'torture', 'Torture test', supportOf(built));

prototype/calibration/torture/gen.py

@@ -0,0 +1,94 @@
+#!/usr/bin/env python3
+"""Torture test: one part with every overhang the tool has to handle, built by the
+site's Full coverage at its defaults. Not a rung coupon: it sets nothing. It shows
+what the site makes on each shape, in one print.
+
+Along a spine block on the plate (x 0-126, y -7..7, 30 mm tall), clockwise from the
+front left:
+
+    front (-y)  ramps at 40 / 30 / 20 deg rising 10 mm, a 20 mm ball, a 2 mm ledge 18 mm out
+    back  (+y)  a table (30 mm flat bridge), a 26 mm mushroom cap on a 5 mm stem, a cave
+    through     sideways holes 3 / 6 / 12 mm across, along y
+    end         an arch tunnel (x 0 end)
+
+Every feature is big enough that its walls are real walls (the first draft's 3-8 mm
+stubs couldn't show whether a wall snaps off clean). Ramps and holes carry their
+angle / size as raised text.
+
+Everything joins the spine, so it is ONE solid piece (coupon.write checks).
+
+    python3 prototype/calibration/torture/gen.py && deno run -A prototype/calibration/torture/build.js
+"""
+import math
+import sys
+from pathlib import Path
+
+import numpy as np
+import trimesh
+from trimesh.creation import cylinder, icosphere
+
+sys.path.insert(0, str(Path(__file__).resolve().parent.parent))
+from coupon import bx, label, write  # noqa: E402
+
+L, HW, H = 126.0, 7.0, 30.0
+add, cut = [], []
+
+
+def ramp(x0, w, angle, z0=4.0, rise=10.0, side=-1):
+    """A wedge off the spine face: underside rising `rise` at `angle` up from the plate."""
+    d = rise / math.tan(math.radians(angle))
+    yz = [(0, z0), (d, z0 + rise), (d, z0 + rise + 2), (0, z0 + rise + 2)]
+    yz = [(side * (HW - 0.5 + y), z) for y, z in yz]
+    if side < 0:
+        yz = yz[::-1]
+    m = trimesh.creation.extrude_polygon(trimesh.path.polygons.Polygon(yz), w)
+    m.apply_transform([[0, 0, 1, x0], [1, 0, 0, 0], [0, 1, 0, 0], [0, 0, 0, 1]])
+    return m
+
+
+def along_y(m):
+    """Rotate a z-axis primitive (cylinder) to run along y."""
+    m.apply_transform(trimesh.transformations.rotation_matrix(math.pi / 2, [1, 0, 0]))
+    return m
+
+
+def at(m, x, y, z):
+    m.apply_translation([x, y, z])
+    return m
+
+
+# the spine
+add.append(bx(0, L, -HW, HW, 0, H))
+
+# FRONT (-y): three ramps, a ball, a thin far ledge
+for x0, a in [(2, 40), (17, 30), (32, 20)]:
+    add.append(ramp(x0, 13, a))
+    d = 10 / math.tan(math.radians(a))
+    add += label(f'{a}', x0 + 6.5, -HW - min(d, 14) / 2 - 0.5, 16, size=5.0)  # on the ramp's top
+add.append(at(icosphere(subdivisions=3, radius=10), 56, -HW - 7, 17))         # ball, low point 7 up
+add.append(bx(70, 94, -HW - 18, -HW + 0.5, 24, 26))                           # 2 mm ledge, 18 out, 24 up
+
+# BACK (+y): table, mushroom, cave
+add += [bx(2, 38, HW - 0.5, HW + 16, 14, 17),                                # table top: 30 mm bridge
+        bx(2, 6, HW + 12, HW + 16, 0, 14), bx(34, 38, HW + 12, HW + 16, 0, 14)]  # its two legs
+add += [at(cylinder(radius=2.5, height=16, sections=32), 56, HW + 14, 8),     # stem on the plate
+        at(cylinder(radius=13, height=3, sections=64), 56, HW + 14, 17.5),    # cap, 13 mm round
+        bx(53.5, 58.5, HW - 0.5, HW + 12, 0, 3)]                               # foot strip to the spine
+add.append(bx(70, 94, HW - 0.5, HW + 14, 0, 24))                              # block holding the cave
+cut.append(bx(73, 91, HW + 0.5, HW + 14.5, 3, 18))                            # cave: open to +y, flat 18 x 14 ceiling
+
+# THROUGH: sideways holes along y, centred high enough that each has a ceiling to hold
+# (their own stretch, x 96-124: nothing else on either face there)
+for x, d in [(99, 3.0), (106, 6.0), (117, 12.0)]:
+    cut.append(at(along_y(cylinder(radius=d / 2, height=2 * HW + 2, sections=48)), x, 0, 16))
+    add += label(f'{d:g}', x, 0, H, size=5.0)                                  # its size, on the spine's top
+
+# END: arch through a block on the x 0 end (along y)
+add.append(bx(-14, 0.5, -HW, HW, 0, 20))
+cut += [at(along_y(cylinder(radius=5, height=2 * HW + 2, sections=48)), -7, 0, 8),
+        bx(-12, -2, -HW - 1, HW + 1, -1, 8)]                                  # arch: 10 wide, 13 high
+
+m = trimesh.boolean.difference([trimesh.boolean.union(add, engine='manifold'),
+                                trimesh.boolean.union(cut, engine='manifold')], engine='manifold')
+m = write(__file__, [m], [])
+print(f'torture part {m.extents.round(1)} mm, {len(m.faces)} triangles')