Phase 3: manufacturing allowance in CutPlan (rough vs final)
Sanding never shrinks the design model; instead the cut plan distinguishes the rough size you cut from the final size you sand to. - CutItem gains final_length_in/final_width_in (+ final_len/final_wid/ has_allowance helpers); length_in/width_in are the ROUGH cut size. - _cut_items(scene, settings): a finished (finish != raw) board is cut oversize by sanding_allowance_in on dimensions actually CUT — length always, width only for sheet goods. Dimensional lumber's section width is the stock as delivered, not padded (Rob's point). note gains "sand to final". - ShopSettings.sanding_allowance_in default 1/32"; serialization additive. - BOM cut list shows "Cut … → final …" and a sanding-allowance footnote. - tests: raw = no allowance, sanded lumber pads length only, plywood pads width too, allowance roundtrips in plan JSON. Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>
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@ -36,7 +36,7 @@ class ShopSettings:
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grain_direction: bool = False # honor grain (future; disables rotation)
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# tolerances — defaults present from day one even before they're in the UI
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mortise_tenon_clearance_in: float = 1 / 32
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sanding_allowance_in: float = 0.0
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sanding_allowance_in: float = 1 / 32 # finished parts cut this much oversize
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reveal_in: float = 0.0
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def to_dict(self) -> dict:
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@ -53,10 +53,24 @@ class CutItem:
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id: str
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part_id: str
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stock: str
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length_in: float
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length_in: float # ROUGH cut size (what you cut from stock)
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width_in: float
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is_sheet: bool
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note: str = "" # e.g. "incl. tenon"
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final_length_in: float = 0.0 # finished size after sanding (0 -> same as rough)
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final_width_in: float = 0.0
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@property
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def final_len(self) -> float:
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return self.final_length_in or self.length_in
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@property
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def final_wid(self) -> float:
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return self.final_width_in or self.width_in
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@property
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def has_allowance(self) -> bool:
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return (self.length_in - self.final_len > _EPS) or (self.width_in - self.final_wid > _EPS)
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@dataclass
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@ -134,15 +148,29 @@ class CutPlan:
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# --------------------------------------------------------------------------
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def _cut_items(scene) -> list:
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def _cut_items(scene, settings: "ShopSettings | None" = None) -> list:
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"""Build the cut demand from the scene. A finished (non-raw) board is cut
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slightly oversize and sanded to final: the allowance is added to dimensions
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we actually CUT — length always; width only for sheet goods (a panel we rip).
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Dimensional lumber's section width is the stock as delivered — not padded."""
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s = settings or ShopSettings()
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allow = s.sanding_allowance_in
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items = []
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for n, p in enumerate(scene.parts, 1):
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ln = cut_length(p)
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final_len = round(cut_length(p), 3)
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final_wid = round(p.section_in[1], 3)
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sheet = is_plywood(p.stock)
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finished = getattr(p, "finish", "raw") != "raw"
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rough_len = round(final_len + allow, 3) if finished else final_len
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rough_wid = round(final_wid + allow, 3) if (finished and sheet) else final_wid
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note = "incl. tenon" if cut_length(p) > p.length_in + _EPS else ""
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if finished and allow > 0:
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note = (note + "; " if note else "") + "sand to final"
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items.append(CutItem(
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id=f"ci{n}", part_id=p.id, stock=p.stock,
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length_in=round(ln, 3), width_in=round(p.section_in[1], 3),
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is_sheet=is_plywood(p.stock),
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note="incl. tenon" if ln > p.length_in + _EPS else ""))
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length_in=rough_len, width_in=rough_wid,
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final_length_in=final_len, final_width_in=final_wid,
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is_sheet=sheet, note=note))
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return items
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@ -405,7 +433,7 @@ def _pack_plywood_seeded(items, stock, s, ids, seeds) -> tuple[list, list]:
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def build_cut_plan(scene, settings: ShopSettings | None = None,
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strategy: str = "decreasing") -> CutPlan:
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s = settings or ShopSettings()
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items = _cut_items(scene)
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items = _cut_items(scene, s)
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by_id = {it.id: it for it in items}
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counter = {"n": 0}
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@ -489,7 +517,7 @@ def reoptimize(scene, base_plan: CutPlan, strategy: str = "decreasing") -> CutPl
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are packed into the free space around locked ones first (free segments on
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seeded sticks / free rectangles on seeded sheets), then onto new stock."""
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s = base_plan.settings
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items = _cut_items(scene)
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items = _cut_items(scene, s)
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locked = [p for sp in base_plan.stock_pieces for p in sp.placements if p.locked]
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locked_ids = {p.item_id for p in locked}
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counter = {"n": 0}
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@ -126,16 +126,25 @@ class BomWindow(QDialog):
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def _cut_text(self) -> str:
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plan = self._plan
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groups = Counter((it.stock, round(it.length_in, 2), round(it.width_in, 2), it.is_sheet)
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groups = Counter((it.stock, round(it.length_in, 2), round(it.width_in, 2),
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round(it.final_len, 2), round(it.final_wid, 2), it.is_sheet)
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for it in plan.items)
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lines = ["CUT LIST", ""]
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for (stock, ln, wd, sheet), n in sorted(groups.items()):
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for (stock, ln, wd, fl, fw, sheet), n in sorted(groups.items()):
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if sheet:
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lines.append(f" {n:>2} × {stock:<8} {_fmt_len(wd)} × {_fmt_len(ln)}"
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f" ({wd * ln / 144 * n:.1f} sq ft)")
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size = f"{_fmt_len(wd)} × {_fmt_len(ln)}"
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extra = f"({wd * ln / 144 * n:.1f} sq ft)"
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else:
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lines.append(f" {n:>2} × {stock:<8} @ {_fmt_len(ln):<9}"
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f" ({board_feet(stock, ln) * n:.1f} bd-ft)")
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size = f"@ {_fmt_len(ln)}"
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extra = f"({board_feet(stock, ln) * n:.1f} bd-ft)"
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row = f" {n:>2} × {stock:<8} {size}"
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if (ln, wd) != (fl, fw): # finished oversize — show final
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final = f"{_fmt_len(fw)} × {_fmt_len(fl)}" if sheet else f"@ {_fmt_len(fl)}"
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row += f" → final {final}"
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lines.append(f"{row:<46} {extra}")
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if any(it.has_allowance for it in plan.items):
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lines += ["", f" (cut sizes include a {_fmt_len(plan.settings.sanding_allowance_in)}"
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" sanding allowance — sand to final)"]
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if not plan.items:
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lines.append(" (nothing to cut yet)")
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return "\n".join(lines)
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@ -290,3 +290,41 @@ def test_custom_settings_kerf():
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s.place("2x4", 48)
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# zero kerf -> both 48" fit in one 96" stick
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assert build_cut_plan(s, settings=ShopSettings(kerf_in=0.0)).score["stock_count"] == 1
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def test_raw_part_has_no_allowance():
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s = Scene()
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s.place("2x4", 24)
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it = build_cut_plan(s).items[0]
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assert it.length_in == 24 and it.final_len == 24 and not it.has_allowance
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def test_sanded_lumber_cut_oversize_in_length_only():
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s = Scene()
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s.place("2x4", 24)
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s.set_finish("p1", "sanded")
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plan = build_cut_plan(s, settings=ShopSettings(sanding_allowance_in=1 / 16))
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it = plan.items[0]
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assert abs(it.length_in - 24.0625) < 0.01 # length padded ~1/16"
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assert it.final_len == 24.0
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assert it.width_in == it.final_wid # lumber width NOT padded
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assert it.has_allowance
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def test_sanded_plywood_pads_width_too():
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s = Scene()
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s.place("ply-3/4", 24, width_in=12)
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s.set_finish("p1", "paint")
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plan = build_cut_plan(s, settings=ShopSettings(sanding_allowance_in=1 / 16))
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it = plan.items[0]
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assert it.length_in > it.final_len and it.width_in > it.final_wid
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def test_allowance_roundtrips_in_plan_json():
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import json
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s = Scene()
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s.place("2x4", 24)
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s.set_finish("p1", "sanded")
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plan = build_cut_plan(s)
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plan2 = CutPlan.from_dict(json.loads(json.dumps(plan.to_dict())))
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assert plan2.items[0].final_len == plan.items[0].final_len
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