fix: clip pockets and triangulation to boundary in plots — no visual crossovers

tools/adaptive-isogrid/src/brain/__main__.py

@@ -64,17 +64,46 @@ def _plot_density(geometry: Dict[str, Any], params: Dict[str, Any], out_path: Pa
 
 
 def _plot_triangulation(geometry: Dict[str, Any], triangulation: Dict[str, Any], out_path: Path) -> None:
+    from shapely.geometry import Polygon as ShapelyPolygon, LineString
+
     verts = triangulation["vertices"]
     tris = triangulation["triangles"]
 
     fig, ax = plt.subplots(figsize=(8, 6), dpi=160)
-    ax.triplot(verts[:, 0], verts[:, 1], tris, color="#1f77b4", lw=0.4, alpha=0.85)
 
     outer = np.asarray(geometry["outer_boundary"])
+    plate_poly = ShapelyPolygon(outer)
+
+    # Draw only triangle edges that are inside the boundary (clipped)
+    drawn_edges = set()
+    for tri in tris:
+        centroid = verts[tri].mean(axis=0)
+        from shapely.geometry import Point
+        if not plate_poly.contains(Point(centroid)):
+            continue
+        for i in range(3):
+            edge = tuple(sorted([tri[i], tri[(i + 1) % 3]]))
+            if edge in drawn_edges:
+                continue
+            drawn_edges.add(edge)
+            p1, p2 = verts[edge[0]], verts[edge[1]]
+            line = LineString([p1, p2])
+            clipped = plate_poly.intersection(line)
+            if clipped.is_empty:
+                continue
+            if clipped.geom_type == "LineString":
+                cx, cy = clipped.xy
+                ax.plot(cx, cy, color="#1f77b4", lw=0.4, alpha=0.85)
+            elif clipped.geom_type == "MultiLineString":
+                for seg in clipped.geoms:
+                    cx, cy = seg.xy
+                    ax.plot(cx, cy, color="#1f77b4", lw=0.4, alpha=0.85)
+
     ax.plot(np.r_[outer[:, 0], outer[0, 0]], np.r_[outer[:, 1], outer[0, 1]], "k-", lw=1.6)
     for hole in geometry.get("holes", []):
         hb = np.asarray(hole["boundary"])
-        ax.plot(np.r_[hb[:, 0], hb[0, 0]], np.r_[hb[:, 1], hb[0, 1]], "r-", lw=1.0)
+        ax.fill(hb[:, 0], hb[:, 1], color="white", zorder=2)
+        ax.plot(np.r_[hb[:, 0], hb[0, 0]], np.r_[hb[:, 1], hb[0, 1]], "r-", lw=1.0, zorder=3)
 
     ax.set_aspect("equal", adjustable="box")
     ax.set_title("Constrained Delaunay Triangulation / Rib Pattern")
@@ -86,16 +115,42 @@ def _plot_triangulation(geometry: Dict[str, Any], triangulation: Dict[str, Any],
 
 
 def _plot_final_profile(geometry, pockets, ribbed_plate, out_path: Path) -> None:
+    from shapely.geometry import Polygon as ShapelyPolygon
+    from matplotlib.patches import PathPatch
+    from matplotlib.path import Path as MplPath
+
     fig, ax = plt.subplots(figsize=(8, 6), dpi=160)
 
     outer = np.asarray(geometry["outer_boundary"])
+    plate_poly = ShapelyPolygon(outer)
     ax.plot(np.r_[outer[:, 0], outer[0, 0]], np.r_[outer[:, 1], outer[0, 1]], "k-", lw=1.8, label="Outer boundary")
 
+    # Draw pockets clipped to the plate boundary — no crossovers
     for pocket in pockets:
         polyline = pocket.get("polyline", pocket.get("vertices", []))
         pv = np.asarray(polyline)
         if len(pv) >= 3:
-            ax.fill(pv[:, 0], pv[:, 1], color="#88ccee", alpha=0.35, lw=0.0)
+            pocket_poly = ShapelyPolygon(pv)
+            if not pocket_poly.is_valid:
+                pocket_poly = pocket_poly.buffer(0)
+            if pocket_poly.is_empty:
+                continue
+            clipped = plate_poly.intersection(pocket_poly)
+            if clipped.is_empty:
+                continue
+            # Draw clipped geometry
+            clip_geoms = [clipped] if clipped.geom_type == "Polygon" else list(clipped.geoms)
+            for cg in clip_geoms:
+                if cg.geom_type != "Polygon" or cg.is_empty:
+                    continue
+                cx, cy = cg.exterior.xy
+                ax.fill(cx, cy, color="#88ccee", alpha=0.35, lw=0.0)
+
+    # Draw holes from geometry
+    for hole in geometry.get("holes", []):
+        hb = np.asarray(hole["boundary"])
+        ax.fill(hb[:, 0], hb[:, 1], color="white", lw=0.0)
+        ax.plot(np.r_[hb[:, 0], hb[0, 0]], np.r_[hb[:, 1], hb[0, 1]], "k-", lw=0.7)
 
     if ribbed_plate.geom_type == "Polygon":
         geoms = [ribbed_plate]

tools/adaptive-isogrid/src/brain/triangulation.py

@@ -224,8 +224,20 @@ def generate_triangulation(geometry, params, max_refinement_passes=3):
         cx = np.mean(all_pts[t, 0])
         cy = np.mean(all_pts[t, 1])
         centroid = Point(cx, cy)
-        # Keep if centroid is inside plate frame and outside keepouts
-        if inner_plate.contains(centroid) and not keepout_union.contains(centroid):
+        # Keep if centroid is inside plate frame and outside keepouts,
+        # AND all 3 vertices are inside the plate boundary (no crossovers)
+        if not inner_plate.contains(centroid):
+            continue
+        if keepout_union.contains(centroid):
+            continue
+        all_inside = True
+        for vi in t:
+            if not plate_poly.contains(Point(all_pts[vi])):
+                # Allow small tolerance (vertex on boundary is OK)
+                if not plate_poly.buffer(0.5).contains(Point(all_pts[vi])):
+                    all_inside = False
+                    break
+        if all_inside:
             keep.append(i)
 
     triangles = triangles[keep] if keep else np.empty((0, 3), dtype=int)