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Remaining Work: No-Go Zones & Warnings

1. No-Go Zone Data Model

1a. NoGoZone — rayforge/machine/models/nogo_zone.py (new)

class NoGoShape(Enum):
    RECT = "rect"          # axis-aligned 2D box (x, y, w, h)
    CYLINDER = "cylinder"  # 3D cylinder (x, y, z, radius, height)
    BOX = "box"            # 3D box (x, y, z, w, h, d)

class NoGoZone:
    """Follow the Laser/RotaryModule pattern: class with changed Signal,
    setter methods, to_dict/from_dict, pickle support, extra dict."""
    uid: str
    name: str
    shape: NoGoShape
    params: Dict[str, float]   # shape-specific dimensions
    enabled: bool = True
    color: Tuple[float, ...] = (1.0, 0.0, 0.0, 0.3)
  • 2D zones use RECT with {x, y, w, h} — checked against workpiece bounding boxes and toolpath XY coordinates.
  • 3D zones use CYLINDER or BOX — additionally checked against Z travel (e.g. rotary chuck extends upward).
  • All coordinates in machine space (mm), within axis_extents.

1b. Integration into Machine

Add to Machine:

self.nogo_zones: Dict[str, NoGoZone] = {}

# Serialization keys in to_dict/from_dict:
# "nogo_zones": [...]

Follow the same dict-by-uid pattern as rotary_modules.

1c. Integration into MachineProfile

Add optional fields to MachineProfile so preset machines can ship with default no-go zones (e.g. Carvera Air knows where its rotary chuck sits).

2. Zone Checking

2a. ZoneChecker — rayforge/machine/models/zone_checker.py (new)

Pure-logic class, no UI dependency:

class ZoneCheckResult:
    zone: NoGoZone
    severity: str          # "warning" | "error"
    message: str
    intersection_type: str  # "bbox" | "toolpath"

class ZoneChecker:
    def __init__(self, machine: Machine):
        self.machine = machine

    def get_active_zones(self) -> List[NoGoZone]:
        """Returns enabled zones + rotary module volumes if configured."""

    def check_bbox(self, bbox: Rect) -> List[ZoneCheckResult]:
        """Check a 2D bounding box against all 2D zones."""

    def check_toolpath(self, ops: Ops) -> List[ZoneCheckResult]:
        """Check ops vertices against zones (2D + optional Z)."""

    def check_rotary_wcs_alignment(self, layer: Layer) -> Optional[str]:
        """If layer is rotary, verify WCS points to rotary axis position."""

Intersection logic: Reuse rayforge/core/geo/polygon.py (polygons_intersect) for 2D. For 3D (Z-axis check against rotary module height), a simple range check suffices.

2b. Where checks run

Check Trigger Location
BBox vs. zones Workpiece moved/resized, zone changed Pipeline WorkPiecePipelineStage or DocEditor command post-hook
Toolpath vs. zones Pipeline produces Ops StepPipelineStage — after ops production, before encoding
Rotary WCS alignment Layer rotary_enabled toggled, WCS changed Layer signal handler in DocEditor

Results emitted via signal:

zone_warnings_changed = Signal()  # sends List[ZoneCheckResult]

3. Warning UI

3a. Toolbar warnings

The app has Toolbar.machine_warning_box for persistent warnings and MainWindow._add_toast() for transient messages. Extend:

  • Rotary WCS mismatch: persistent warning in toolbar. Clicking opens hardware page to fix WCS.
  • Zone violation: toast with severity. For severity="error", block job execution (disable "Generate G-code" button, like existing can_export).

3b. Canvas visual feedback

When a zone violation is active, the intersecting zone renderer pulses or turns red. Follows how the jog widget uses add_css_class("warning") for limit violations.

3c. ZoneWarningBanner (optional)

A collapsible Gtk.InfoBar above the canvas listing active zone violations. More detailed than toasts, less intrusive than a dialog.

4. No-Go Zones Settings UI

New NogoZonesPage in rayforge/ui_gtk/machine/, registered in the machine settings dialog sidebar:

No-Go Zones
├── [ListBox] List of zones (name, shape, enabled toggle, delete button)
├── [Button] "Add Zone"
│   └── Dialog: choose shape → set dimensions & position
└── [SpinRow] per-zone: X, Y, W, H (rect) or X, Y, Z, Radius, Height (cylinder/box)

Follows PreferencesGroupWithButton + TrackedPreferencesPage pattern.

5. Key Design Decisions

  1. Machine-scoped: Zones belong to the physical machine, persist in its YAML config. Documents are portable across machines.

  2. Coordinate space: All zone coordinates in machine space. Existing MachineSpace transforms handle conversion.

  3. 3D-first collision: Full 3D collision detection from day one. 2D rect zones are degenerate 3D zones (Z height = 0), not a separate 2D system.

  4. Reuse geometry: polygons_intersect() from core/geo/polygon.py for XY-plane intersection. Simple range checks for Z-axis bounds. No new 3D geometry library needed.

  5. Non-blocking warnings: Zone violations warn but don't prevent design. Only block at job execution time.