From 708e1a242855936e03963cd6366b57c4f272fe94 Mon Sep 17 00:00:00 2001
From: Ahmed Alshaybani <shibo@Mac.lan>
Date: Wed, 14 Oct 2026 02:00:03 +0200
Subject: [PATCH] test: reproduce PMP22650 unroutable gap fill

---
 .../pmp22650-unroutable-gap-fill.snap.svg     |  44 ++++++++
 .../pmp22650-unroutable-gap-fill.test.ts      | 100 ++++++++++++++++++
 2 files changed, 144 insertions(+)
 create mode 100644 tests/solver/repros/pmp22650-unroutable-gap-fill/__snapshots__/pmp22650-unroutable-gap-fill.snap.svg
 create mode 100644 tests/solver/repros/pmp22650-unroutable-gap-fill/pmp22650-unroutable-gap-fill.test.ts

diff --git a/tests/solver/repros/pmp22650-unroutable-gap-fill/__snapshots__/pmp22650-unroutable-gap-fill.snap.svg b/tests/solver/repros/pmp22650-unroutable-gap-fill/__snapshots__/pmp22650-unroutable-gap-fill.snap.svg
new file mode 100644
index 0000000..a0fc536
--- /dev/null
+++ b/tests/solver/repros/pmp22650-unroutable-gap-fill/__snapshots__/pmp22650-unroutable-gap-fill.snap.svg
@@ -0,0 +1,44 @@
+<svg width="640" height="640" viewBox="0 0 640 640" xmlns="http://www.w3.org/2000/svg"><rect width="100%" height="100%" fill="white"/><g><rect data-type="rect" data-label="0.1 mm minimum-width trace envelope" data-x="0" data-y="0" x="89.85331455490575" y="153.98310591293045" width="460.2933708901885" height="363.8726445743989" fill="rgba(239, 68, 68, 0.12)" stroke="#dc2626" stroke-width="0.010992857142857143"/></g><g><rect data-type="rect" data-label="5.05994 mm × 0.00276 mm generated gap fill" data-x="0" data-y="0" x="89.85331455490575" y="330.89798570506406" width="460.2933708901885" height="10.04288499013171" fill="#22c55e" stroke="#15803d" stroke-width="0.010992857142857143"/></g><text data-type="text" data-label="1 unroutable gap-fill node generated (40× vertical scale)" data-x="0" data-y="2.35" x="320" y="122.14424951267051" fill="black" font-size="16.374269005847953" font-family="sans-serif" text-anchor="middle" dominant-baseline="text-after-edge">1 unroutable gap-fill node generated (40× vertical scale)</text><g id="crosshair" style="display: none"><line id="crosshair-h" y1="0" y2="640" stroke="#666" stroke-width="0.5"/><line id="crosshair-v" x1="0" x2="640" stroke="#666" stroke-width="0.5"/><text id="coordinates" font-family="monospace" font-size="12" fill="#666"></text></g><script><![CDATA[
+              document.currentScript.parentElement.addEventListener('mousemove', (e) => {
+                const svg = e.currentTarget;
+                const rect = svg.getBoundingClientRect();
+                const x = e.clientX - rect.left;
+                const y = e.clientY - rect.top;
+                const crosshair = svg.getElementById('crosshair');
+                const h = svg.getElementById('crosshair-h');
+                const v = svg.getElementById('crosshair-v');
+                const coords = svg.getElementById('coordinates');
+                
+                crosshair.style.display = 'block';
+                h.setAttribute('x1', '0');
+                h.setAttribute('x2', '640');
+                h.setAttribute('y1', y);
+                h.setAttribute('y2', y);
+                v.setAttribute('x1', x);
+                v.setAttribute('x2', x);
+                v.setAttribute('y1', '0');
+                v.setAttribute('y2', '640');
+
+                // Calculate real coordinates using inverse transformation
+                const matrix = {"a":90.96816114359974,"c":0,"e":320,"b":0,"d":-90.96816114359974,"f":335.9194282001299};
+                // Manually invert and apply the affine transform
+                // Since we only use translate and scale, we can directly compute:
+                // x' = (x - tx) / sx
+                // y' = (y - ty) / sy
+                const sx = matrix.a;
+                const sy = matrix.d;
+                const tx = matrix.e; 
+                const ty = matrix.f;
+                const realPoint = {
+                  x: (x - tx) / sx,
+                  y: (y - ty) / sy // Flip y back since we used negative scale
+                }
+                
+                coords.textContent = `(${realPoint.x.toFixed(2)}, ${realPoint.y.toFixed(2)})`;
+                coords.setAttribute('x', (x + 5).toString());
+                coords.setAttribute('y', (y - 5).toString());
+              });
+              document.currentScript.parentElement.addEventListener('mouseleave', () => {
+                document.currentScript.parentElement.getElementById('crosshair').style.display = 'none';
+              });
+            ]]></script></svg>
\ No newline at end of file
diff --git a/tests/solver/repros/pmp22650-unroutable-gap-fill/pmp22650-unroutable-gap-fill.test.ts b/tests/solver/repros/pmp22650-unroutable-gap-fill/pmp22650-unroutable-gap-fill.test.ts
new file mode 100644
index 0000000..63ca87e
--- /dev/null
+++ b/tests/solver/repros/pmp22650-unroutable-gap-fill/pmp22650-unroutable-gap-fill.test.ts
@@ -0,0 +1,100 @@
+import { expect, test } from "bun:test"
+import { getSvgFromGraphicsObject } from "graphics-debug"
+import { ExpandEdgesToEmptySpaceSolver } from "../../../../lib/solvers/GapFillSolver/ExpandEdgesToEmptySpaceSolver"
+import type { CapacityMeshNode } from "../../../../lib/types/capacity-mesh-types"
+
+const lowerRegion: CapacityMeshNode = {
+  capacityMeshNodeId: "cmn_225",
+  center: { x: 20.772797999999998, y: 136.5996595 },
+  width: 6.392004,
+  height: 4.920137000000011,
+  layer: "top",
+  availableZ: [0, 1, 2, 3, 4, 5, 6, 7],
+}
+
+const upperRegion: CapacityMeshNode = {
+  capacityMeshNodeId: "cmn_226",
+  center: { x: 20.106765499999998, y: 140.774321 },
+  width: 5.059939,
+  height: 3.423665999999997,
+  layer: "top",
+  availableZ: [0, 1, 2, 3, 4, 5, 6, 7],
+}
+
+const platedHoleRegion: CapacityMeshNode = {
+  capacityMeshNodeId: "cmn_5328",
+  center: { x: 23.71173566, y: 140.13472861999998 },
+  width: 2.150000779999999,
+  height: 2.150000779999999,
+  layer: "top",
+  availableZ: [0, 1, 2, 3, 4, 5, 6, 7],
+  _containsObstacle: true,
+  _containsTarget: true,
+}
+
+test("PMP22650 does not fill a gap narrower than minTraceWidth", async () => {
+  const solver = new ExpandEdgesToEmptySpaceSolver({
+    inputMeshNodes: [lowerRegion, upperRegion, platedHoleRegion],
+    segmentsWithAdjacentEmptySpace: [
+      {
+        parent: lowerRegion,
+        start: { x: 17.576795999999998, y: 139.059728 },
+        end: { x: 22.63673527, y: 139.059728 },
+        z: 7,
+        facingDirection: "y+",
+      },
+    ],
+  })
+
+  solver.solve()
+
+  const expandedNodes = solver
+    .getOutput()
+    .expandedSegments.map(({ newNode }) => newNode)
+  expect(expandedNodes).toHaveLength(1)
+  expect(expandedNodes[0]).toMatchObject({
+    width: 5.059939270000001,
+    height: 0.002759999999966567,
+  })
+  const verticalScale = 40
+  await expect(
+    getSvgFromGraphicsObject(
+      {
+        title:
+          "PMP22650 gap fill compared with minTraceWidth (40× vertical scale)",
+        coordinateSystem: "cartesian",
+        rects: [
+          {
+            center: { x: 0, y: 0 },
+            width: 5.059939270000001,
+            height: 0.1 * verticalScale,
+            fill: "rgba(239, 68, 68, 0.12)",
+            stroke: "#dc2626",
+            label: "0.1 mm minimum-width trace envelope",
+          },
+          ...expandedNodes.map((node) => ({
+            center: { x: 0, y: 0 },
+            width: node.width,
+            height: node.height * verticalScale,
+            fill: "#22c55e",
+            stroke: "#15803d",
+            label: `${node.width.toFixed(5)} mm × ${node.height.toFixed(5)} mm generated gap fill`,
+          })),
+        ],
+        texts: [
+          {
+            x: 0,
+            y: 2.35,
+            text: `${expandedNodes.length} unroutable gap-fill node generated (40× vertical scale)`,
+            fontSize: 0.18,
+            anchorSide: "bottom_center",
+          },
+        ],
+      },
+      {
+        width: 1200,
+        height: 300,
+      },
+    ),
+  ).toMatchSvgSnapshot(import.meta.path)
+})