Meshcutter fully working

.github/workflows/auto-merge-release.yml

@@ -0,0 +1,28 @@
+# Auto-merge release-please PRs
+# Automatically merges release-please PRs once CI passes
+
+name: Auto-merge Release PRs
+
+on:
+  pull_request:
+    branches: [releases]
+    types: [opened, synchronize, reopened]
+
+jobs:
+  auto-merge:
+    name: Auto-merge release-please PR
+    runs-on: ubuntu-latest
+    # Only run for release-please PRs
+    if: startsWith(github.head_ref, 'release-please--')
+
+    permissions:
+      contents: write
+      pull-requests: write
+
+    steps:
+      - name: Enable auto-merge
+        uses: peter-evans/enable-pull-request-automerge@v3
+        with:
+          token: ${{ secrets.GITHUB_TOKEN }}
+          pull-request-number: ${{ github.event.pull_request.number }}
+          merge-method: squash

.github/workflows/ci.yml

@@ -1,5 +1,5 @@
 # CI - runs on PRs to releases branch
-# Full test matrix, linting, and build validation
+# Separated jobs for faster feedback and clearer results
 
 name: CI
 
@@ -23,13 +23,13 @@ jobs:
         run: pip install black flake8
 
       - name: Check formatting with black
-        run: black --check --diff microfinity/ tests/
+        run: black --check --diff microfinity/ meshcutter/ tests/
 
       - name: Lint with flake8
-        run: flake8 microfinity/ tests/ --max-line-length=120 --extend-ignore=E203,W503,F401,F403,F405,E402,F821,W293,W605,F841
+        run: flake8 microfinity/ meshcutter/ tests/ --max-line-length=120 --extend-ignore=E203,W503,F401,F403,F405,E402,F821,W293,W605,F841
 
-  test:
-    name: Test (Python ${{ matrix.python-version }})
+  test-microfinity:
+    name: Test microfinity (Python ${{ matrix.python-version }})
     runs-on: ubuntu-latest
     strategy:
       fail-fast: false
@@ -48,18 +48,61 @@ jobs:
         run: |
           pip install --upgrade pip
           pip install cadquery-ocp cadquery cqkit
-          pip install pytest pytest-cov
+          pip install pytest
           pip install -e .
 
-      - name: Run full test suite
-        run: pytest -v --cov=microfinity --cov-report=xml
+      - name: Run microfinity tests
+        run: pytest tests/ --ignore=tests/test_meshcutter -v
 
-      - name: Upload coverage
-        uses: codecov/codecov-action@v4
-        if: matrix.python-version == '3.11'
+  test-meshcutter-unit:
+    name: Test meshcutter unit (Python ${{ matrix.python-version }})
+    runs-on: ubuntu-latest
+    strategy:
+      fail-fast: false
+      matrix:
+        python-version: ["3.9", "3.10", "3.11", "3.12"]
+
+    steps:
+      - uses: actions/checkout@v4
+
+      - name: Set up Python ${{ matrix.python-version }}
+        uses: actions/setup-python@v5
+        with:
+          python-version: ${{ matrix.python-version }}
+
+      - name: Install dependencies
+        run: |
+          pip install --upgrade pip
+          pip install cadquery-ocp cadquery cqkit
+          pip install manifold3d
+          pip install pytest
+          pip install -e .
+
+      - name: Run meshcutter unit tests
+        run: pytest tests/test_meshcutter -m "not integration" -v
+
+  test-meshcutter-integration:
+    name: Test meshcutter integration
+    runs-on: ubuntu-latest
+
+    steps:
+      - uses: actions/checkout@v4
+
+      - name: Set up Python
+        uses: actions/setup-python@v5
         with:
-          files: ./coverage.xml
-          fail_ci_if_error: false
+          python-version: "3.11"
+
+      - name: Install dependencies
+        run: |
+          pip install --upgrade pip
+          pip install cadquery-ocp cadquery cqkit
+          pip install manifold3d
+          pip install pytest
+          pip install -e .
+
+      - name: Run meshcutter integration tests
+        run: pytest tests/test_meshcutter -m "integration" -v
 
   build:
     name: Build Package

.github/workflows/sync-to-dev.yml

@@ -0,0 +1,54 @@
+# Sync releases back to dev after release-please creates a release
+# This ensures dev stays up-to-date with version bumps and changelog updates
+
+name: Sync to Dev
+
+on:
+  push:
+    branches: [releases]
+    paths:
+      - 'pyproject.toml'
+      - 'microfinity/__init__.py'
+      - 'CHANGELOG.md'
+
+jobs:
+  sync:
+    name: Sync releases to dev
+    runs-on: ubuntu-latest
+    # Only run if this looks like a release-please commit
+    if: contains(github.event.head_commit.message, 'chore(releases)') || contains(github.event.head_commit.message, 'chore(main)')
+
+    steps:
+      - uses: actions/checkout@v4
+        with:
+          fetch-depth: 0
+          token: ${{ secrets.GITHUB_TOKEN }}
+
+      - name: Configure git
+        run: |
+          git config user.name "github-actions[bot]"
+          git config user.email "github-actions[bot]@users.noreply.github.com"
+
+      - name: Sync version files to dev
+        run: |
+          # Get the version from releases branch
+          VERSION=$(grep -m1 'version = ' pyproject.toml | cut -d'"' -f2)
+          echo "Syncing version $VERSION to dev"
+
+          # Checkout dev branch
+          git checkout dev
+
+          # Cherry-pick the version bump changes (if they apply cleanly)
+          # Or directly update the version files
+          git checkout releases -- pyproject.toml microfinity/__init__.py CHANGELOG.md
+
+          # Check if there are changes
+          if git diff --quiet; then
+            echo "No changes to sync"
+            exit 0
+          fi
+
+          # Commit and push
+          git add pyproject.toml microfinity/__init__.py CHANGELOG.md
+          git commit -m "chore: sync version $VERSION from releases"
+          git push origin dev

CLAUDE.md

@@ -0,0 +1,105 @@
+# Claude Project Context: Microfinity
+
+This file provides context for Claude when working on this project.
+
+## Project Overview
+
+**Microfinity** is a Python library for creating Gridfinity-compatible objects using CadQuery. It includes:
+
+1. **microfinity/** - CadQuery-based generator for boxes, baseplates, and spacers
+2. **meshcutter/** - Mesh-based tool to convert 1U Gridfinity boxes to micro-divided feet
+
+## Key Architecture Decisions
+
+### Meshcutter: Replace-Base Approach
+
+The meshcutter uses a **replace-base pipeline** (not boolean subtraction) to convert 1U feet to micro-feet:
+
+1. **Trim** the input mesh above z=5mm (keeps walls and interior)
+2. **Generate** fresh micro-feet base using microfinity's construction path
+3. **Union** the trimmed top with the new base
+
+This produces geometry **identical** to natively-generated micro boxes (<1mm³ difference).
+
+**Important**: The legacy boolean subtraction approach has been deprecated and removed.
+
+### Gridfinity Constants
+
+All Gridfinity constants should come from `meshcutter/core/constants.py`, which re-exports from `microfinity.core.constants`.
+
+Key values:
+- `GRU = 42.0` - 1U pitch (mm)
+- `GR_TOL = 0.5` - Clearance between feet
+- `GR_BASE_HEIGHT = 4.75` - Foot height
+- `GR_BASE_CLR = 0.25` - Clearance above foot
+- `Z_SPLIT_HEIGHT = 5.0` - Where we cut between top and base
+
+## Important Files
+
+### Core Modules
+- `meshcutter/core/replace_base.py` - Main replace-base pipeline
+- `meshcutter/core/constants.py` - Centralized constants
+- `meshcutter/core/mesh_utils.py` - Mesh conversion utilities
+- `meshcutter/core/cq_utils.py` - CadQuery utilities
+- `meshcutter/core/grid_utils.py` - Grid/offset calculations
+
+### CLI
+- `meshcutter/cli/meshcut.py` - Command-line interface
+
+### Tests
+- `tests/test_meshcutter/test_golden.py` - Golden comparison tests
+- `tests/test_meshcutter/golden_utils.py` - Test utilities
+
+## Refactoring Tracking
+
+**IMPORTANT**: When completing refactoring tasks, update `REFACTOR_TODO.md` to mark items as complete.
+
+The refactoring TODO file tracks:
+- DRY elimination (utility modules)
+- Module updates
+- Test creation
+- CI setup
+
+## Testing
+
+### Golden Tests
+Golden tests compare meshcutter output against microfinity-generated references:
+- Reference meshes are generated on-demand (not stored)
+- Acceptance threshold: <1mm³ total geometric difference
+- Test configurations: 1x1x1, 2x3x2, 1x1x3, 3x3x1
+
+### Running Tests
+```bash
+# All meshcutter tests
+pytest tests/test_meshcutter/ -v
+
+# Just golden tests
+pytest tests/test_meshcutter/test_golden.py -v
+
+# Quick unit tests (skip slow golden tests)
+pytest tests/test_meshcutter/ -v -m "not golden"
+```
+
+## Code Style
+
+- **Line length**: 120 characters (configured in pyproject.toml)
+- **Formatter**: Black
+- **Type hints**: Use throughout, especially for public APIs
+- **Docstrings**: Google style
+
+## Common Tasks
+
+### Adding a New Micro-Division Size
+1. Update `meshcutter/core/grid_utils.py` if offset calculations change
+2. Add test configuration to `tests/test_meshcutter/test_golden.py`
+3. Update `docs/TODO_FUTURE_DIVISIONS.md`
+
+### Updating Constants
+1. Check if constant exists in `microfinity.core.constants`
+2. If yes, re-export in `meshcutter/core/constants.py`
+3. If no, add to meshcutter-specific section
+
+### Debugging Mesh Issues
+1. Use `mesh_utils.get_mesh_diagnostics()` for mesh info
+2. Export intermediate meshes with `mesh.export('/tmp/debug.stl')`
+3. View in external tool (MeshLab, Blender)