Blender/addons/Mesh Outline Projector/__init__.py

@@ -14,6 +14,61 @@ from mathutils import Vector
 from mathutils.bvhtree import BVHTree
 
 
+def point_in_polygon_2d(point, polygon_verts):
+    """Check if a 2D point is inside a 2D polygon using ray casting algorithm"""
+    x, y = point[0], point[1]
+    n = len(polygon_verts)
+    inside = False
+    
+    p1x, p1y = polygon_verts[0]
+    for i in range(1, n + 1):
+        p2x, p2y = polygon_verts[i % n]
+        if y > min(p1y, p2y):
+            if y <= max(p1y, p2y):
+                if x <= max(p1x, p2x):
+                    if p1y != p2y:
+                        xinters = (y - p1y) * (p2x - p1x) / (p2y - p1y) + p1x
+                    if p1x == p2x or x <= xinters:
+                        inside = not inside
+        p1x, p1y = p2x, p2y
+    
+    return inside
+
+
+def point_near_polygon_edge(point, polygon_verts, tolerance=0.05):
+    """Check if a point is very close to any polygon edge"""
+    x, y = point[0], point[1]
+    n = len(polygon_verts)
+    
+    for i in range(n):
+        p1x, p1y = polygon_verts[i]
+        p2x, p2y = polygon_verts[(i + 1) % n]
+        
+        # Calculate distance from point to line segment
+        # Vector from p1 to p2
+        dx = p2x - p1x
+        dy = p2y - p1y
+        
+        if dx == 0 and dy == 0:
+            # Degenerate edge
+            dist = ((x - p1x)**2 + (y - p1y)**2)**0.5
+        else:
+            # Parameter t for closest point on line segment
+            t = max(0, min(1, ((x - p1x) * dx + (y - p1y) * dy) / (dx * dx + dy * dy)))
+            
+            # Closest point on line segment
+            closest_x = p1x + t * dx
+            closest_y = p1y + t * dy
+            
+            # Distance to closest point
+            dist = ((x - closest_x)**2 + (y - closest_y)**2)**0.5
+        
+        if dist < tolerance:
+            return True
+    
+    return False
+
+
 def get_object_outline_edges_2d(obj, context):
     """Get the outline edges of an object when viewed from above (Z-axis)"""
     print(f"\n=== Getting outline edges for: {obj.name} ===")
@@ -232,94 +287,157 @@ def project_outline_to_mesh(context, source_obj, target_obj, outline_edges):
     bm.faces.ensure_lookup_table()
     bm.edges.ensure_lookup_table()
     
-    print(f"  Creating vertical cutting planes from outline edges...")
+    print(f"  Creating outline curve for knife projection...")
     
     # Get transformation matrix to convert from world to target local space
     target_matrix_inv = target_obj.matrix_world.inverted()
     
-    # Identify horizontal edges (those in the XY plane that form the perimeter)
-    # These are edges where both vertices have similar Z values
+    # Get horizontal perimeter edges
     horizontal_edges = []
     for v1, v2 in outline_edges:
         z_diff = abs(v1.z - v2.z)
         xy_dist = ((v1.x - v2.x)**2 + (v1.y - v2.y)**2)**0.5
         
-        # If edge is mostly horizontal (small Z difference, significant XY distance)
         if z_diff < 0.01 and xy_dist > 0.01:
             horizontal_edges.append((v1, v2))
     
-    print(f"  Found {len(horizontal_edges)} horizontal perimeter edges")
+    print(f"  Found {len(horizontal_edges)} horizontal perimeter edges (before deduplication)")
     
-    # For each horizontal edge, create a vertical cutting plane
-    cuts_performed = 0
-    for i, (v1_world, v2_world) in enumerate(horizontal_edges):
-        # Transform edge vertices to target's local space
-        v1_local = target_matrix_inv @ v1_world
-        v2_local = target_matrix_inv @ v2_world
+    # Deduplicate edges
+    unique_edges_normalized = []
+    tolerance = 0.01
     
-        # Edge vector in XY (local space)
-        edge_vec = Vector((v2_local.x - v1_local.x, v2_local.y - v1_local.y, 0))
-        edge_vec.normalize()
+    for v1, v2 in horizontal_edges:
+        if v1.x < v2.x or (abs(v1.x - v2.x) < tolerance and v1.y < v2.y):
+            edge_normalized = (v1, v2)
+        else:
+            edge_normalized = (v2, v1)
         
-        # Plane normal perpendicular to edge (in XY, pointing inward/outward)
-        plane_normal = Vector((-edge_vec.y, edge_vec.x, 0))
-        plane_normal.normalize()
+        is_duplicate = False
+        for existing_v1, existing_v2 in unique_edges_normalized:
+            if (abs(edge_normalized[0].x - existing_v1.x) < tolerance and 
+                abs(edge_normalized[0].y - existing_v1.y) < tolerance and
+                abs(edge_normalized[1].x - existing_v2.x) < tolerance and 
+                abs(edge_normalized[1].y - existing_v2.y) < tolerance):
+                is_duplicate = True
+                break
         
-        # Plane point (use v1 in local space)
-        plane_co = v1_local.copy()
+        if not is_duplicate:
+            unique_edges_normalized.append(edge_normalized)
     
-        if i < 3:
-            print(f"    Cut {i}: plane at ({plane_co.x:.2f}, {plane_co.y:.2f}) [local], normal ({plane_normal.x:.2f}, {plane_normal.y:.2f})")
+    print(f"  Deduplicated to {len(unique_edges_normalized)} unique edges")
     
-        # Perform bisect
-        geom = bm.verts[:] + bm.edges[:] + bm.faces[:]
-        result = bmesh.ops.bisect_plane(
-            bm,
-            geom=geom,
-            dist=0.001,
-            plane_co=plane_co,
-            plane_no=plane_normal,
-            clear_outer=False,
-            clear_inner=False
-        )
-        cuts_performed += 1
+    # Build ordered polygon from edges for point-in-polygon testing
+    # Start with first edge
+    polygon_verts_2d = [unique_edges_normalized[0][0], unique_edges_normalized[0][1]]
+    used_edges = {0}
     
-    print(f"  Performed {cuts_performed} cutting plane operations")
+    # Connect edges to form a closed loop
+    for _ in range(len(unique_edges_normalized) - 1):
+        last_point = polygon_verts_2d[-1]
         
-    bmesh.update_edit_mesh(target_obj.data)
+        # Find next connected edge
+        for i, (v1, v2) in enumerate(unique_edges_normalized):
+            if i in used_edges:
+                continue
             
-    # Refresh bmesh references after cuts
+            # Check if this edge connects to our last point
+            v1_2d = (v1.x, v1.y)
+            v2_2d = (v2.x, v2.y)
+            last_2d = (last_point.x, last_point.y)
+            
+            tolerance = 0.01
+            if abs(v1_2d[0] - last_2d[0]) < tolerance and abs(v1_2d[1] - last_2d[1]) < tolerance:
+                polygon_verts_2d.append(v2)
+                used_edges.add(i)
+                break
+            elif abs(v2_2d[0] - last_2d[0]) < tolerance and abs(v2_2d[1] - last_2d[1]) < tolerance:
+                polygon_verts_2d.append(v1)
+                used_edges.add(i)
+                break
+    
+    # Remove duplicate endpoint if polygon is closed
+    if len(polygon_verts_2d) > 0:
+        first = polygon_verts_2d[0]
+        last = polygon_verts_2d[-1]
+        if abs(first.x - last.x) < 0.01 and abs(first.y - last.y) < 0.01:
+            polygon_verts_2d = polygon_verts_2d[:-1]
+    
+    # Convert to 2D coordinates in world space for polygon testing
+    polygon_2d_world = [(v.x, v.y) for v in polygon_verts_2d]
+    
+    print(f"  Built polygon with {len(polygon_2d_world)} vertices for point-in-polygon testing")
+    print(f"  Polygon vertices (world space):")
+    for i, (x, y) in enumerate(polygon_2d_world):
+        print(f"    Vertex {i}: ({x:.2f}, {y:.2f})")
+    
+    # Create curve object from unique edges
+    curve_data = bpy.data.curves.new(name=f"{source_obj.name}_outline", type='CURVE')
+    curve_data.dimensions = '3D'
+    
+    for v1, v2 in unique_edges_normalized:
+        spline = curve_data.splines.new('POLY')
+        spline.points.add(1)
+        spline.points[0].co = (v1.x, v1.y, v1.z, 1)
+        spline.points[1].co = (v2.x, v2.y, v2.z, 1)
+    
+    curve_obj = bpy.data.objects.new(f"{source_obj.name}_outline", curve_data)
+    context.collection.objects.link(curve_obj)
+    
+    print(f"  Created curve with {len(unique_edges_normalized)} splines")
+    
+    # Set view to top orthographic
+    original_view_data = None
+    for area in context.screen.areas:
+        if area.type == 'VIEW_3D':
+            for space in area.spaces:
+                if space.type == 'VIEW_3D':
+                    from mathutils import Quaternion
+                    original_view_data = {
+                        'rotation': space.region_3d.view_rotation.copy(),
+                        'perspective': space.region_3d.view_perspective,
+                        'distance': space.region_3d.view_distance
+                    }
+                    space.region_3d.view_rotation = Quaternion((1.0, 0.0, 0.0, 0.0))
+                    space.region_3d.view_perspective = 'ORTHO'
+                    break
+    
+    # Switch back to object mode to select objects
+    bpy.ops.object.mode_set(mode='OBJECT')
+    
+    # Deselect all
+    bpy.ops.object.select_all(action='DESELECT')
+    
+    # Select curve and target
+    curve_obj.select_set(True)
+    target_obj.select_set(True)
+    context.view_layer.objects.active = target_obj
+    
+    # Switch to edit mode for knife_project
+    bpy.ops.object.mode_set(mode='EDIT')
+    bpy.ops.mesh.select_all(action='DESELECT')
+    
+    # Use knife project
+    print(f"  Running knife_project...")
+    bpy.ops.mesh.knife_project(cut_through=False)
+    
+    # Restore view
+    if original_view_data:
+        for area in context.screen.areas:
+            if area.type == 'VIEW_3D':
+                for space in area.spaces:
+                    if space.type == 'VIEW_3D':
+                        space.region_3d.view_rotation = original_view_data['rotation']
+                        space.region_3d.view_perspective = original_view_data['perspective']
+                        space.region_3d.view_distance = original_view_data['distance']
+                        break
+    
+    # Get bmesh for material assignment
     bm = bmesh.from_edit_mesh(target_obj.data)
     bm.faces.ensure_lookup_table()
     
     print(f"  Mesh cutting complete, now assigning materials...")
     
-    # Calculate 2D bounding box of the outline (in world space)
-    min_x_world = min(min(v1.x, v2.x) for v1, v2 in outline_edges)
-    max_x_world = max(max(v1.x, v2.x) for v1, v2 in outline_edges)
-    min_y_world = min(min(v1.y, v2.y) for v1, v2 in outline_edges)
-    max_y_world = max(max(v1.y, v2.y) for v1, v2 in outline_edges)
-    
-    print(f"  Outline 2D bounds (world space): X=[{min_x_world:.2f}, {max_x_world:.2f}], Y=[{min_y_world:.2f}, {max_y_world:.2f}]")
-    
-    # Transform bounds to target object's local space (reuse matrix from cutting)
-    # Transform the 4 corners of the bounding box
-    corner_min_min = target_matrix_inv @ Vector((min_x_world, min_y_world, 0))
-    corner_min_max = target_matrix_inv @ Vector((min_x_world, max_y_world, 0))
-    corner_max_min = target_matrix_inv @ Vector((max_x_world, min_y_world, 0))
-    corner_max_max = target_matrix_inv @ Vector((max_x_world, max_y_world, 0))
-    
-    # Get new bounds in local space
-    all_x = [corner_min_min.x, corner_min_max.x, corner_max_min.x, corner_max_max.x]
-    all_y = [corner_min_min.y, corner_min_max.y, corner_max_min.y, corner_max_max.y]
-    
-    min_x_local = min(all_x)
-    max_x_local = max(all_x)
-    min_y_local = min(all_y)
-    max_y_local = max(all_y)
-    
-    print(f"  Outline 2D bounds (target local space): X=[{min_x_local:.2f}, {max_x_local:.2f}], Y=[{min_y_local:.2f}, {max_y_local:.2f}]")
-    
     # Assign material to faces within bounds
     if material_index >= 0:
         source_min_z_world = min(min(v1.z, v2.z) for v1, v2 in outline_edges)
@@ -327,24 +445,60 @@ def project_outline_to_mesh(context, source_obj, target_obj, outline_edges):
         source_max_z_local = (target_matrix_inv @ Vector((0, 0, source_max_z_world))).z
         
         print(f"  Source Z max: {source_max_z_world:.2f} (world), {source_max_z_local:.2f} (target local)")
+        print(f"  Material assignment: ALL vertices inside or on edge (tolerance: 0.05)")
         
         faces_assigned = 0
+        faces_rejected_outside_polygon = 0
+        faces_rejected_z = 0
+        
         for face in bm.faces:
             face_center = face.calc_center_median()
             
-            # Face center is already in target's local space (we're in edit mode)
-            # Check if within XY bounds and below source
-            if (min_x_local <= face_center.x <= max_x_local and 
-                min_y_local <= face_center.y <= max_y_local and 
-                face_center.z < source_max_z_local):
+            # First check Z (quick rejection)
+            below_z = face_center.z < source_max_z_local
+            if not below_z:
+                faces_rejected_z += 1
+                continue
             
+            # Check if ALL vertices are inside or on/near the polygon boundary
+            all_verts_inside = True
+            verts_checked = 0
+            
+            for vert in face.verts:
+                vert_world = target_obj.matrix_world @ vert.co
+                
+                # Check Z first
+                if vert_world.z >= source_max_z_world:
+                    all_verts_inside = False
+                    break
+                
+                # Check if vertex is inside polygon OR on/near the edge (with tolerance)
+                inside = point_in_polygon_2d((vert_world.x, vert_world.y), polygon_2d_world)
+                on_edge = point_near_polygon_edge((vert_world.x, vert_world.y), polygon_2d_world, tolerance=0.05)
+                
+                if not (inside or on_edge):
+                    all_verts_inside = False
+                    break
+                    
+                verts_checked += 1
+            
+            if all_verts_inside and verts_checked > 0:
                 face.material_index = material_index
                 faces_assigned += 1
                 
-                if faces_assigned <= 3:
-                    print(f"    Assigned material to face at ({face_center.x:.2f}, {face_center.y:.2f}, {face_center.z:.2f}) [local]")
+                if faces_assigned <= 5:
+                    face_center_world = target_obj.matrix_world @ face_center
+                    print(f"    ✓ Face {faces_assigned}: ({face_center.x:.2f}, {face_center.y:.2f}, {face_center.z:.2f}) [local] -> ({face_center_world.x:.2f}, {face_center_world.y:.2f}) [world]")
+            else:
+                faces_rejected_outside_polygon += 1
+                if faces_rejected_outside_polygon <= 5:
+                    face_center_world = target_obj.matrix_world @ face_center
+                    print(f"    ✗ Outside polygon: ({face_center.x:.2f}, {face_center.y:.2f}, {face_center.z:.2f}) [local] -> ({face_center_world.x:.2f}, {face_center_world.y:.2f}) [world]")
         
-        print(f"  Assigned material to {faces_assigned} faces")
+        print(f"  Material assignment results:")
+        print(f"    Assigned: {faces_assigned}")
+        print(f"    Rejected - Outside polygon: {faces_rejected_outside_polygon}")
+        print(f"    Rejected - Z too high: {faces_rejected_z}")
     
     bmesh.update_edit_mesh(target_obj.data)
     
@@ -352,6 +506,11 @@ def project_outline_to_mesh(context, source_obj, target_obj, outline_edges):
     bpy.ops.object.mode_set(mode='OBJECT')
     print(f"  Returned to OBJECT mode")
     
+    # Clean up temporary curve object
+    bpy.data.objects.remove(curve_obj, do_unlink=True)
+    bpy.data.curves.remove(curve_data)
+    print(f"  Cleaned up temporary curve")
+    
     # Verify material assignment
     if material_index >= 0:
         print(f"\n  Post-assignment verification:")