🔍 Post-Fixture Raycast Analysis - Blade Generation System

💡 Hybrid Approach Concept

After a fixture is built using solid geometry (booleans, sections), raycast scanning provides point-by-point verification that booleans cannot easily provide. This is validation AFTER construction, not during.

1. Contact Validation

Verify part actually contacts blades where intended.

Ray origin: Part contact face centroid Ray direction: Face normal (toward blade) Expected: Hit blade within tolerance Checks: - Confirm contact points match design intent - Detect gaps or unexpected clearances - Verify part is seated correctly

2. Clearance Verification

Confirm non-contact faces don't interfere with blades.

Ray origin: Non-contact face sample points Ray direction: Toward nearest blade Expected: Distance > minimum clearance Checks: - Verify adequate gap at non-support areas - Detect unexpected interference - Confirm part can be loaded/unloaded

3. Weld Accessibility

Verify torch can reach all weld locations.

Ray origin: Weld bead endpoints Ray directions: Multiple angles (approach vectors) Expected: At least one clear path per weld Checks: - Clear line-of-sight for torch approach - Verify approach angle is feasible - Flag obstructed welds for review

4. Clamp Load Paths

Verify clamping forces transfer to support blades.

Ray origin: Clamp contact points Ray direction: Through part toward blade contacts Expected: Continuous load path exists Checks: - Part won't flex or pivot under clamp force - Load distributes to multiple blades - No unsupported cantilever regions

5. Gravity Stability

Confirm part is stable under gravity (3+ non-collinear contacts).

Ray origin: Part CoG region sample points Ray direction: -Z (gravity) Expected: 3+ contacts forming stable triangle Checks: - Part won't tip when released - Identify minimum stable contact set - Flag marginal stability conditions

6. Visual/Inspection Access

Verify critical features visible for QC inspection.

Ray origin: Inspection station position Ray direction: Toward critical feature Expected: Unobstructed line of sight Checks: - Can QC see critical features? - Weld inspection visibility - Dimension measurement access

7. Chip/Coolant Drainage

Verify chips and coolant drain clear during machining.

Ray origin: Pocket floor sample points Ray direction: -Z (gravity drain) Expected: Clear path to fixture base or drain Checks: - Chips won't accumulate in pockets - Coolant flow paths exist - No trapped debris areas

Implementation Strategy

Phase	Components
Phase 1: Core Infrastructure	`fxRaycastPoint`, `fxRaycastGrid`, `fxRaycastFromFace`
Phase 2: Analysis Modules	`fxValidateContacts`, `fxCheckClearances`, `fxAnalyzeWeldAccess`, `fxCheckStability`
Phase 3: Integration	Auto-run after fixture generation, pass/fail reports, visual markers, JSON/XML export

Hybrid Approach Benefits

Aspect	Solid Boolean	Raycast	Hybrid Winner
Profile generation	✓ Fast, accurate	✗ Slow, sampling	Boolean for build
Point-specific checks	✗ Overkill	✓ Precise	Raycast for verify
Accessibility	✗ Can't check	✓ Line-of-sight	Raycast
Performance	Medium	Depends on density	Optimized per task

📦 Planned Deliverables

fxRaycastPoint.ovm - Single ray, returns hit point/distance/face

fxRaycastGrid.ovm - Grid of rays, returns hit array

fxValidateContacts.ovm - Contact validation report

fxAnalyzeWeldAccess.ovm - Weld accessibility report

fxCheckStability.ovm - Gravity stability analysis

POST_FIXTURE_RAYCAST_ANALYSIS.md - Full specification (exists)

🔍 Post-Fixture Raycast Analysis (PLANNED)