From 20dc5fd96aa07ef34aa90f9008931ad1cf046cd9 Mon Sep 17 00:00:00 2001
From: Ryan Malloy <ryan@supported.systems>
Date: Mon, 13 Jul 2026 12:47:06 -0600
Subject: [PATCH] Support exact octagon tiles in the search tree clearance
 checks

Add optional exact/seg fields to TreeShape for a diagonal trace tile: tile holds
the bounding box for broad-phase bucketing, exact holds the tight octagon copper,
and seg=(a,b,half_width) rebuilds the clearance region on demand. Every
orthogonal tile leaves both None and takes the identical box code path, so the
box-only tree stays byte-for-byte unchanged (whole suite green).

clearance_conflict now tests a stored diagonal tile with an exact 2-D overlap;
clearance_conflict_shape checks a diagonal trace's clearance octagon against
stored copper; has_violation runs the exact octagon test whenever either tile is
diagonal and the plain box overlap otherwise. All exact-integer via Simplex
intersection.
---
 src/freeroute/board/search_tree.py | 53 ++++++++++++++++++++++++++++--
 1 file changed, 50 insertions(+), 3 deletions(-)

diff --git a/src/freeroute/board/search_tree.py b/src/freeroute/board/search_tree.py
index 9706aa3..caaa49b 100644
--- a/src/freeroute/board/search_tree.py
+++ b/src/freeroute/board/search_tree.py
@@ -18,7 +18,7 @@ from __future__ import annotations
 
 from dataclasses import dataclass
 
-from freeroute.geometry import IntBox
+from freeroute.geometry import IntBox, Simplex, overlaps_2d, segment_octagon
 
 __all__ = ["TreeShape", "ShapeSearchTree"]
 
@@ -31,6 +31,13 @@ class TreeShape:
     board items (pads, keepouts). The routing DRC only counts violations that
     involve at least one routed tile — two source-design pads that are already
     closer than the clearance are a property of the input, not of the router.
+
+    ``exact`` / ``seg`` are set only for a 45-degree (diagonal) trace tile: ``tile``
+    is then the bounding box (broad-phase only), ``exact`` is the tight octagon
+    copper :class:`~freeroute.geometry.Simplex`, and ``seg`` is ``(a, b,
+    half_width)`` so the clearance region can be rebuilt exactly on demand. For
+    every orthogonal tile both are ``None`` and all code paths are byte-identical
+    to the box-only tree.
     """
 
     owner: int  # a caller-chosen id grouping the tiles of one item/connection
@@ -38,10 +45,22 @@ class TreeShape:
     layers: frozenset[int]
     tile: IntBox
     routed: bool = False
+    exact: Simplex | None = None
+    seg: tuple | None = None  # (a: IntPoint, b: IntPoint, half_width: int)
 
     def on_layer(self, layer: int) -> bool:
         return layer in self.layers
 
+    def clearance_region(self, clearance: int):
+        """This tile's copper grown outward by ``clearance`` (a convex tile).
+
+        Orthogonal: the box offset by ``clearance``. Diagonal: the octagon of the
+        segment swept by ``half_width + clearance`` (exact integer superset)."""
+        if self.seg is None:
+            return self.tile.offset(clearance)
+        a, b, half_width = self.seg
+        return segment_octagon(a, b, half_width + clearance)
+
 
 class ShapeSearchTree:
     """Bounding-box spatial hash of :class:`TreeShape` with exact queries."""
@@ -110,7 +129,27 @@ class ShapeSearchTree:
         for shape in self.overlapping(expanded):
             if shape.net_no == net_no or not shape.on_layer(layer):
                 continue
-            if shape.tile.overlaps(expanded):
+            if shape.exact is not None:
+                if overlaps_2d(shape.exact, expanded):
+                    return True
+            elif shape.tile.overlaps(expanded):
+                return True
+        return False
+
+    def clearance_conflict_shape(
+        self, region, net_no: int, layer: int
+    ) -> bool:
+        """True if the convex ``region`` (a clearance-grown copper tile, e.g. a
+        diagonal trace's octagon) overlaps a different net's copper on ``layer``.
+
+        ``region`` already carries the clearance, so this tests a bare 2-D overlap
+        against each candidate's exact tile (or its box). Used to check a diagonal
+        trace whose growth is not an axis-aligned box."""
+        for shape in self.overlapping(region.bounding_box()):
+            if shape.net_no == net_no or not shape.on_layer(layer):
+                continue
+            other = shape.exact if shape.exact is not None else shape.tile
+            if overlaps_2d(region, other):
                 return True
         return False
 
@@ -124,6 +163,7 @@ class ShapeSearchTree:
         """
         for shape in self.all_shapes():
             expanded = shape.tile.offset(clearance)
+            grown = None  # exact clearance region, built lazily only for diagonals
             for other in self.overlapping(expanded):
                 if other is shape or other.net_no == shape.net_no:
                     continue
@@ -131,6 +171,13 @@ class ShapeSearchTree:
                     continue  # static input pair (e.g. pad vs pad) — not a routing DRC
                 if not (shape.layers & other.layers):
                     continue
-                if other.tile.overlaps(expanded):
+                if shape.exact is None and other.exact is None:
+                    if other.tile.overlaps(expanded):  # byte-identical box path
+                        return shape
+                    continue
+                if grown is None:
+                    grown = shape.clearance_region(clearance)
+                other_tile = other.exact if other.exact is not None else other.tile
+                if overlaps_2d(grown, other_tile):
                     return shape
         return None