Mesh booleans

MeshBoolean combines two solids — union, difference or intersection — and cuts one with a plane or with another's surface. BooleanOperation names which. MeshCollision is the other end of the same mesh: the boxes and the triangle soup a physics world can be given.

Cutting a doorway through a wall by putting a box where the doorway goes. It is the most requested tool in every block-out toolset and the one every toolset ships last, because a boolean that is nearly right produces geometry that looks correct and is not.

You do not want it for a bevel or an inset. Those are mesh operations, they know which faces they were given, and they are exact by construction.

Every mesh boolean that produces holes produces them for one reason: a classification near zero answered wrongly, and the two sides of a cut stopped agreeing about which side they were on. That is not a tolerance to tune. It is a question with an exact answer.

⚠ Null rather than an empty mesh when the result is nothing. Subtracting a solid from itself is a legitimate thing to ask for and its answer is that there is no solid — which a caller has to be able to tell from "the operation failed", because one deletes an entity and the other must not.

⚠ A plane is three points, and they are the ones that defined it. A face's supporting plane is recorded as three corners of the original operand and never recomputed, so classifying any original vertex against any original plane is one call to ExactPredicates.Orient3D over inputs that were never arithmetic. A normal and an offset derived in floating point would be a fourth number that disagrees with the three it came from — which is exactly the disagreement that opens a crack between a wall and the floor it is flush with.

⚠ A vertex made by a split remembers the plane it was made on. Its position is arithmetic and so is inexact; its membership is not. Asked which side of that plane it is on, it answers "on it" from the record rather than from a subtraction, for ever, through every later split — so the two faces either side of a cut can never be told apart by it. A point on a segment also lies on every plane both its endpoints lie on, so membership propagates through a split.

⚠ What that does not buy: a split vertex against a plane it was not made on. Three planes meeting at a point is a position computed in floating point. The fully plane-based answer is a four-plane determinant, which is a predicate this engine does not have. What is exact is every original vertex against every original plane, and every derived vertex against the planes it was derived on — which between them are the cases a block-out is made of.

Face groups travel, so the reveal a cut exposed is selectable as a group of its own:

A trim removes the material and leaves the opening bare, which a subtract does not:

⚠ A boolean produces T-junctions by construction and they are repaired. A plane splits every face it crosses and no face it merely touches, so the face beside a cut face keeps an edge whose middle is now somebody else's corner. Every BSP boolean has this and most of them ignore it, because a renderer that only sees triangles mostly gets away with it — an editable mesh does not. MeshOperations.Stitch is the repair and runs on every result.

⚠ A non-manifold edge in a result is an answer rather than a defect. Two solids that touch along an edge and nowhere else have a union with a non-manifold edge in it. EditMesh.Validate reports it, for the reason it reports every other one.

• Editable meshes — the structure, and what Validate reports.
• Mesh operations — the verbs that are exact by construction, including Stitch.
• Booleans in the editor — non-destructive operands, and the handoff.
• Block-out shapes — what the operands usually are.