From 4f0aa7f7b64850a833809f65bc4c042c899a1a75 Mon Sep 17 00:00:00 2001
From: Wassim SAMAD <wass08@gmail.com>
Date: Wed, 15 Jul 2026 20:10:50 -0400
Subject: [PATCH] fix(core): prevent unbounded slab corner miters (#500)

* fix(core): bound slab corner miters

* style(core): format slab miter fix
---
 packages/core/src/lib/slab-polygon.test.ts | 29 ++++++++++++++++++++++
 packages/core/src/lib/slab-polygon.ts      | 26 ++++++++++++++++---
 2 files changed, 51 insertions(+), 4 deletions(-)

diff --git a/packages/core/src/lib/slab-polygon.test.ts b/packages/core/src/lib/slab-polygon.test.ts
index d86006c6..45490c1e 100644
--- a/packages/core/src/lib/slab-polygon.test.ts
+++ b/packages/core/src/lib/slab-polygon.test.ts
@@ -753,6 +753,35 @@ describe('getRenderableSlabPolygon', () => {
     ])
     expect(poly).toHaveLength(6)
   })
+
+  test('nearly collinear corners do not create unbounded wall-offset miters', () => {
+    const stored = [
+      [3.1318685080276216, -4.3412497001265],
+      [11.261660174864861, -4.341249992437693],
+      [11.26165987489183, -1.3166851233565569],
+      [3.131868208054532, -1.3166857310453555],
+      [1.7318390128066048, -1.3166857522417288],
+      [1.7318388127796835, -4.341249921322843],
+    ] as Array<[number, number]>
+    const poly = getRenderableSlabPolygon(slabOf(stored, false), {
+      walls: [
+        wallOf([1.7318387751077626, -4.323741654294752], [11.300000049514956, -4.341249931281993]),
+      ],
+      siblingSlabs: [],
+    })
+
+    const storedExtent = Math.max(...stored.flat().map(Math.abs))
+    const renderedExtent = Math.max(...poly.flat().map(Math.abs))
+    const longestEdge = Math.max(
+      ...poly.map((point, index) => {
+        const next = poly[(index + 1) % poly.length]!
+        return Math.hypot(point[0] - next[0], point[1] - next[1])
+      }),
+    )
+
+    expect(renderedExtent - storedExtent).toBeLessThan(0.2)
+    expect(longestEdge).toBeLessThan(8.4)
+  })
 })
 
 describe('snapSlabEdgeToWallBand', () => {
diff --git a/packages/core/src/lib/slab-polygon.ts b/packages/core/src/lib/slab-polygon.ts
index 23a196e2..5b121adb 100644
--- a/packages/core/src/lib/slab-polygon.ts
+++ b/packages/core/src/lib/slab-polygon.ts
@@ -74,6 +74,8 @@ const WALL_LATERAL_TIE_EPSILON = 0.02
 const CURVED_WALL_SAMPLE_SEGMENTS = 32
 const SLAB_SEAM_ELEVATION_EPSILON = 1e-4
 const DEFAULT_SLAB_ELEVATION = 0.05
+/** Prevent near-parallel offset lines from producing unbounded corner spikes. */
+const MAX_CORNER_MITER_RATIO = 10
 
 export type SlabPolygonContext = {
   /** Walls on the slab's level. */
@@ -748,7 +750,9 @@ function offsetPolygonPerEdge(
     const last = spans[spans.length - 1]!
     const first = subSpans[j]![0]!
     const [ax, az] = pointAt(i, last.start, last.offset)
-    const [bx, bz] = pointAt(j, first.start, first.offset)
+    const endI = pointAt(i, last.end, last.offset)
+    const startJ = pointAt(j, first.start, first.offset)
+    const [bx, bz] = startJ
     const frameI = frames[i]!
     const frameJ = frames[j]!
     const denom = frameI.dx * frameJ.dz - frameI.dz * frameJ.dx
@@ -756,11 +760,25 @@ function offsetPolygonPerEdge(
       // Parallel edges have no unique intersection. Emit both offset
       // endpoints — collinear edges with different offsets need the step
       // between them.
-      push(pointAt(i, last.end, last.offset))
-      push([bx, bz])
+      push(endI)
+      push(startJ)
     } else {
       const t = ((bx - ax) * frameJ.dz - (bz - az) * frameJ.dx) / denom
-      push([ax + t * frameI.dx, az + t * frameI.dz])
+      const intersection: [number, number] = [ax + t * frameI.dx, az + t * frameI.dz]
+      const miterReach = Math.max(
+        Math.hypot(intersection[0] - endI[0], intersection[1] - endI[1]),
+        Math.hypot(intersection[0] - startJ[0], intersection[1] - startJ[1]),
+      )
+      const offsetScale = Math.max(Math.abs(last.offset), Math.abs(first.offset), 1e-9)
+      if (
+        !(Number.isFinite(intersection[0]) && Number.isFinite(intersection[1])) ||
+        miterReach > offsetScale * MAX_CORNER_MITER_RATIO
+      ) {
+        push(endI)
+        push(startJ)
+      } else {
+        push(intersection)
+      }
     }
   }