Phase 1: Foundation Complete
Established core infrastructure for VDM management, face extraction, and wire body processing.
- ✓ VDM management patterns (allocVDM, freeVDM, data passing)
- ✓ Face extraction from solid bodies
- ✓ Wire body creation and manipulation
- ✓ Wire to kurve conversion
- ✓ Basic solid extrusion and boolean operations
📦 Deliverables
fxGetFreeKurve.ovm, fxRotateWireToXYPlane.ovm, VDM utilities
Phase 2: Rotation Technique Discovery Complete
Analyzed working 2019 codebase to identify the proven rotation technique for blade positioning.
- ✓ Studied _4fxComputeBladeEdge2019.ovm
- ✓ Identified rotation axis = blade line endpoints
- ✓ Documented the 90°/-90° rotation technique
- ✓ Understood sculpting zone workflow (work while flat)
📦 Key Insight
Rotation axis is simply (xStart, yStart, 0) to (xEnd, yEnd, 0) - not face normals!
Phase 2b: SLD Command Mastery Complete
Discovered and documented critical SLD commands for blade slice extraction and taper application.
- ✓ SLD SEC (Section) - blade slice extraction with double-cut technique
- ✓ SLD TAP (Taper) - draft angle application to pocket faces
- ✓ SLD PUT FAC - programmatic face set building
- ✓ Face normal filtering for correct face selection
- ✓ Created comprehensive SLD_COMMAND_REFERENCE_FULL.html
📦 Deliverables
fxTestTaperVisual.ovm - working blade slice + taper test
SLD_COMMAND_REFERENCE_FULL.html - 73 commands documented
Phase 3: Simple Blade Generation In Progress
Implement single-segment blade generation using the proven rotation technique.
- ✓ fxCreateBladeSegment.ovm created
- ◐ Fix transformation in fxBladeFromSection.ovm
- ○ Test with rectangular part
- ○ Verify blade wraps part correctly
- ○ Edge modification integration
📦 Deliverables
fxBladeFromSection.ovm (fixed), fxCreateBladeSegment.ovm
Phase 4: Zigzag Blade System In Progress
Multi-segment blade paths with corner handling for formed sheet metal parts.
- ✓ fxZigzagBlade.ovm - main orchestrator
- ✓ fxCornerHandling.ovm - three corner modes
- ✓ fxTestZigzagBlade.ovm - test harness
- ○ Test Mode 0: Overlap + Union
- ○ Test Mode 1: Miter cut
- ○ Test Mode 2: Radius blend
- ○ Bend compensation calculation
📦 Deliverables
fxZigzagBlade.ovm, fxCreateBladeSegment.ovm, fxCornerHandling.ovm
Phase 5: Flat Pattern & DXF Output Pending
Generate flat patterns with bend allowances for manufacturing output.
- ○ Calculate flat pattern from 3D zigzag
- ○ Apply bend allowance formulas
- ○ Generate outline kurve for cutting
- ○ Mark bend lines on separate layer
- ○ Clean unused layers before DXF export - Quick utility to purge empty/unused layers
- ○ DXF export with proper scaling
📦 Deliverables
fxCalcFlatPattern.ovm, fxExportBladeDXF.ovm, fxCleanUnusedLayers.ovm
Phase 5b: Laser Cut Optimization Features Pending
Add laser-specific features to blade DXF output for optimal cutting and material handling.
🔺 Laser Pickup Points (Pierce Points)
Small V-notch or semicircle on non-mating edges to provide a consistent laser pierce/start location.
🔗 Micro-Joints / Tabs
Small uncut segments that keep blade pieces attached to the sheet skeleton during laser cutting.
📦 Deliverables
fxPiercePoint.ovm, fxMicroJoints.ovm, fxNonContactEdgeDetect.ovm
Phase 6: Test Mode Framework Pending
Standardized test harness for validating macro functionality.
- ○ Define test mode number conventions
- ○ Create test output formatting utilities
- ○ Implement "run all tests" mode (99)
- ○ Add visual grid test mode (100) for geometric tests
- ○ Create test result logging to file
📦 Deliverables
fxTestRunner.ovm - main test orchestrator
fxTestUtils.ovm - assertion and logging utilities
test_results.log - output file format
Phase 7: Blade Orphan Detection Pending
Identify blades that are not connected to the baseplate or other blades.
- ○ Query all blade bodies by attribute/layer
- ○ Check each blade has slot connection to base OR another blade
- ○ Use
sld intto test body intersection - ○ Flag orphans with warning color/attribute
- ○ Generate orphan report
📦 Deliverables
fxDetectOrphans.ovm - orphan detection
fxValidateFixture.ovm - full fixture validation suite
Phase 8: Blade Identity & Numbering Pending
Handle the "one blade vs multiple blades" decision for connected segments.
- ○ Design blade group data model
- ○ Segment-to-blade relationship tracking
- ○ Automatic "can bend as one" detection
- ○ Manufacturing ID assignment system
- ○ Blade label generation for DXF
📦 Deliverables
fxBladeIdentity.ovm, fxBladeGroupManager.ovm
Phase 9: Advanced Features Pending
Edge treatments, weight reduction, and curved path support.
- ○ Taper angle on blade edges
- ○ Gripper features
- ○ Weight reduction cutouts
- ○ Arc segment support (curved paths)
- ○ Collision detection between blades
📦 Deliverables
fxBladeEdgeMods.ovm (enhanced), fxArcSegment.ovm
Phase 10: Gravity Offset System In Progress
Variable pocket offset based on gravity direction for optimal part support.
- ✓ Core construction geometry approach
- ✓ Line-to-line gravity offset
- ✓ Line-to-arc gravity offset
- ✓ Arc-to-line gravity offset
- ◐ Arc-to-arc gravity offset (fallback to uniform)
- ○ Multi-direction grid test (Mode 100)
- ○ 'NONE' skip mode (no gravity processing)
- ○ Auto-gravity detection from part orientation
📦 Deliverables
fxGravityOffsetConstruction.ovm, fxTestGravityOffset.ovm
Phase 11: Part Topology Categorization Pending
Automatic detection and classification of part types to drive fixture strategy.
- ○ TUBE/PIPE detection (cylindrical bodies)
- ○ PLATE detection (flat, single thickness)
- ○ SHEET_METAL detection (bent, needs welding consideration)
- ○ STRUCTURAL detection (beams, angles, channels)
- ○ OTHER classification for complex shapes
- ○ Feed classification into fixture strategy selection
📦 Deliverables
fxPartTopology.ovm, fxFixtureStrategy.ovm
Phase 12: Weld Export System Pending
Export weld bead geometry for robotic welding systems. See dedicated section above for details.
📦 Deliverables
fxWeldExport.ovm, fxWeldUnion.ovm, fxTorchVector.ovm
Phase 13: Part Alignment System Pending
3-point origin matching for modified CAD imports. When customers re-export parts with different origins, realign to original fixture.
- ○ Store original part origin reference points
- ○ Detect origin shift in re-imported parts
- ○ Calculate transformation matrix from 3-point match
- ○ Apply alignment to re-imported geometry
- ○ Verify alignment with visual feedback
📦 Deliverables
fxPartAlignment.ovm - 3-point alignment utility
fxStoreOriginRef.ovm - save reference points
Phase 14: Integration & Testing Pending
Full system integration with existing fixture workflow and comprehensive testing.
- ○ Integration with fixture plate generation
- ○ Full workflow testing with real parts
- ○ Performance optimization
- ○ Error handling improvements
- ○ User documentation & training materials
📦 Deliverables
Complete integrated system, user manual, training guide