Tools:

------
Bugfix #6847: Previous fix for "spikes" when using booleans caused creation
of faces with only two unique vertices ("eekadoodles").  This patch cleans up
the test for triangles with near-colinear vertices so PHANTOM faces can be
used again, and also adds a hack for now which removes any eekadoodle faces.

I haven't figured out yet exactly how the faces are being created; if I can
do so and fix it the hack will be removed.

3 files changed, 45 insertions, 10 deletions

diff --git a/intern/boolop/intern/BOP_Face2Face.cpp b/intern/boolop/intern/BOP_Face2Face.cpp
index 745c64eaa97..9c8ee9f7787 100644
--- a/intern/boolop/intern/BOP_Face2Face.cpp
+++ b/intern/boolop/intern/BOP_Face2Face.cpp
@@ -1,4 +1,7 @@
 /**
+ *
+ * $Id$
+ *
  * ***** BEGIN GPL/BL DUAL LICENSE BLOCK *****
  *
  * This program is free software; you can redistribute it and/or
@@ -23,7 +26,7 @@
  *
  * The Original Code is: all of this file.
  *
- * Contributor(s): none yet.
+ * Contributor(s): Marc Freixas, Ken Hughes
  *
  * ***** END GPL/BL DUAL LICENSE BLOCK *****
  */
@@ -427,17 +430,11 @@ void BOP_mergeVertexs(BOP_Mesh *mesh, unsigned int firstFace)
 						// v2 ~= v3
 						mesh->replaceVertexIndex(v2,v3);
 					} else {
-#if 0
-	/*
-	 * for now, don't just remove "co-linear" faces; some of these faces
-	 * being removed are real and cause other things to break
-	 */
 						// all differents
 						if (BOP_collinear(vertex1,vertex2,vertex3)) {
 							// collinear triangle 
 							face->setTAG(PHANTOM);
 						}
-#endif
 					}
 				}
 			}
diff --git a/intern/boolop/intern/BOP_MathUtils.cpp b/intern/boolop/intern/BOP_MathUtils.cpp
index 7a0210247eb..251bbb9e138 100644
--- a/intern/boolop/intern/BOP_MathUtils.cpp
+++ b/intern/boolop/intern/BOP_MathUtils.cpp
@@ -1,4 +1,7 @@
 /**
+ *
+ * $Id$
+ *
  * ***** BEGIN GPL/BL DUAL LICENSE BLOCK *****
  *
  * This program is free software; you can redistribute it and/or
@@ -23,7 +26,7 @@
  *
  * The Original Code is: all of this file.
  *
- * Contributor(s): none yet.
+ * Contributor(s): Marc Freixas, Ken Hughes
  *
  * ***** END GPL/BL DUAL LICENSE BLOCK *****
  */
@@ -115,7 +118,12 @@ bool BOP_collinear(const MT_Point3& p1, const MT_Point3& p2, const MT_Point3& p3
 {
 	MT_Vector3 v1 = p2 - p1;
 	MT_Vector3 v2 = p3 - p2;
-	
+
+	/* normalize vectors before taking their cross product, so its length 
+     * has some actual meaning */
+	v1.normalize();	
+	v2.normalize();
+
 	MT_Vector3 w = v1.cross(v2);
 	
 	return (BOP_comp(w.x(),0.0) == 0) && (BOP_comp(w.y(),0.0) == 0) && (BOP_comp(w.z(),0.0) == 0);
diff --git a/intern/boolop/intern/BOP_Merge.cpp b/intern/boolop/intern/BOP_Merge.cpp
index fb5bfbc0e7b..5839d38181a 100644
--- a/intern/boolop/intern/BOP_Merge.cpp
+++ b/intern/boolop/intern/BOP_Merge.cpp
@@ -1,4 +1,7 @@
 /**
+ *
+ * $Id$
+ *
  * ***** BEGIN GPL/BL DUAL LICENSE BLOCK *****
  *
  * This program is free software; you can redistribute it and/or
@@ -23,7 +26,7 @@
  *
  * The Original Code is: all of this file.
  *
- * Contributor(s): none yet.
+ * Contributor(s): Marc Freixas, Ken Hughes
  *
  * ***** END GPL/BL DUAL LICENSE BLOCK *****
  */
@@ -57,6 +60,32 @@ void BOP_Merge::mergeFaces(BOP_Mesh *m, BOP_Index v)
 	// Merge faces
 	mergeFaces();
 
+	/*
+	 * HACK: somehow triangular faces are being created with two vertices the
+	 * same.  If it's happening in BOP_Mesh::replaceVertexIndex() we should
+	 * be catching it, so either it's not happening there or we aren't
+	 * catching it (duh).  Until we figure this out, this hack cleans things.
+	 * 
+	 * Test for any invalid faces: if any two vertices are the same of a
+	 * triangle, the face is broken.  Further, I don't believe it's possible
+	 * to have any quads at this point, so if we find one send a message
+	 * to stdout.
+	 */
+
+	BOP_Faces faces = m_mesh->getFaces();
+	const BOP_IT_Faces ifacesIEnd = (faces.end());
+	for(BOP_IT_Faces faceI=faces.begin();faceI!=ifacesIEnd;faceI++) {
+		if ((*faceI)->getTAG() != BROKEN ) {
+			BOP_Index i1 = (*faceI)->getVertex(0);
+			BOP_Index i2 = (*faceI)->getVertex(1);
+			BOP_Index i3 = (*faceI)->getVertex(2);
+			if ( (*faceI)->size() == 4)
+				cout << "BOP_Merge::mergeFaces found a quad: this is an error" << endl;
+			if (i1 == i2 || i2 == i3 || i3 == i1 )
+				(*faceI)->setTAG(BROKEN);
+		}
+	}
+
 	do {
 		// Add quads ...
 		cont = createQuads();
@@ -592,6 +621,7 @@ bool BOP_Merge::createQuads()
 	
 	// Get mesh faces
 	BOP_Faces faces = m_mesh->getFaces();
+
 	
     // Merge mesh triangles
 	const BOP_IT_Faces facesIEnd = (faces.end()-1);