Fix merge_coplanar_faces creating holes in mesh for non-simple polygon boundaries by Copilot · Pull Request #258 · sintefmath/Jutul.jl

Copilot · 2026-02-15T10:58:16Z

merge_coplanar_faces produces holes and volume errors (~3%) when applied after layered_mesh with non-planar surfaces. The greedy _chain_boundary_edges algorithm silently drops nodes at branch points (degree > 2), producing incomplete polygons that pass the convexity check on a wrong subset of nodes.

# Reproducer
g = CartesianMesh((10, 10, 10), (1000.0, 1000.0, 100.0))
mesh = UnstructuredMesh(g)
surfs = [depth_grid_to_surface(xs, ys, fill(50.0, N, N) .+ rand(N, N) .* 10.0)]
result, _ = layered_mesh(mesh, surfs)
result = merge_coplanar_faces(result)  # holes at layer intersection

Changes

_merge_face_group!: Add two guards before merging a coplanar cluster:
1. Verify all boundary nodes have degree exactly 2 (simple polygon). Skip merge otherwise.
2. Verify the chain covers all boundary nodes. Skip merge otherwise.
Skipped clusters fall through to the existing fallback loop which preserves the original faces as-is.
Test: Add merge_coplanar_faces after layered_mesh preserves volume covering the reported scenario with a deterministic non-planar surface.

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…aries When multiple coplanar faces are merged, the boundary of the merged polygon may have branch points (nodes with degree != 2). The greedy chain algorithm cannot correctly trace such boundaries, producing incomplete polygons that create holes in the mesh. Add a boundary degree check before chaining: if any boundary node has a degree other than 2, skip the merge for that cluster and leave the original faces unchanged. Also verify that the chain covers all boundary nodes as a safety net. Co-authored-by: moyner <454871+moyner@users.noreply.github.com>

Co-authored-by: moyner <454871+moyner@users.noreply.github.com>

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Copilot AI assigned Copilot and moyner Feb 15, 2026

Copilot started work on behalf of moyner February 15, 2026 10:58 View session

Copilot AI and others added 3 commits February 15, 2026 11:28

Add test for merge_coplanar_faces volume preservation after layered_mesh

22a1e25

Co-authored-by: moyner <454871+moyner@users.noreply.github.com>

Address review: fix comment wording in merge_faces.jl and test

bc0a94b

Co-authored-by: moyner <454871+moyner@users.noreply.github.com>

Copilot AI changed the title ~~[WIP] Fix holes in mesh created by merge coplanar faces~~ Fix merge_coplanar_faces creating holes in mesh for non-simple polygon boundaries Feb 15, 2026

Copilot AI requested a review from moyner February 15, 2026 11:35

Copilot finished work on behalf of moyner February 15, 2026 11:35

Update layered.jl

7a1da08

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Fix merge_coplanar_faces creating holes in mesh for non-simple polygon boundaries#258

Fix merge_coplanar_faces creating holes in mesh for non-simple polygon boundaries#258
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Copilot AI commented Feb 15, 2026 •

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