Strange Error in Render

This displays fine, until I try a top-level render (either in code or from
the menu...)

Then I get:
ERROR: CGAL error in CGALUtils::applyBinaryOperator difference: CGAL ERROR:
assertion violation! Expr: G.mark(v1,0)==G.mark(v2,0)&&
G.mark(v1,1)==G.mark(v2,1) File:
/mxe/usr/x86_64-w64-mingw32.static.posix/include/CGAL/Nef_S2/SM_overlayer.h
Line: 303

Thoughts?

[code]

/////////////////////////////////////////// MAIN CODE
////////////////////////////////

include <utilities/utils.scad>

module insertHole(depth)  {
  //scale([25.4,25.4,25.4]) {
    /*#10 insert*/ insH=6;insR =3.75;
         coneR1=insR-.5;coneR2=insR+.5;rad=2.25;
    insert(depth,insH,coneR1,coneR2,rad);
  //}
}

//module roundTube(height,radius,wallTh,x,y,z)
//NAME
////////////////////////// DIMENSIONS  //////////////////////////
mm=25.4;
latchW=46;
latchH=20;
latchD=6;
side=5;
w=80;
oW=150;
l=200;
slotW=64;
slotH=8.5;
slotMin=56;
gapY=18; //28 from end of slot
latchZ=28; //to top of slot...
//inset=46;
tabD=11;
rnd=3;
bagR=8;
pomR=25;
rackH=40;
fl=5;
scR=(.294*mm)/2;
sR=.078*mm;
tabW=24;
footR=tabW/2;

rightC=(2.5*mm) -.078;  //screw radius   //w/2-((w-slotW)/4);
leftC=-rightC;

module slot()  {
    translate([0,l/2+bagR+bagR,0])
    rotate([90,0,0])
    linear_extrude(height = l+20, center= true)
   
polygon([[-slotW/2,0],[slotW/2,0],[slotMin/2,slotH],[-slotMin/2,slotH]]);
}

module infill(length)  {
    render()
    rotate([-90,0,0])
    rotate([0,90,0])
    pillarFillet(bagR,length,rnd);
}  

module latchHole() {
    roundVol(-latchW/2,latchW/2,-50,50,slotH,latchZ,rnd);
    roundVol(-latchW/2,latchW/2,-tabD+latchD,10,slotH,50,rnd);
    translate([-latchW/2,-side-side,latchZ+ side])
    rotate([0,90,0]) render()
            pillarFillet(side,latchW,rnd);
}
module arch() {
    translate([w/2-pomR,0,rackH-pomR])
    rotate([90,0,0])
    invQuarterRoundCyl(pomR,tabD+rnd,rnd);
}
module leftarch() {
    mirror([1,0,0]) arch();
}

module pommel()  {
    difference() {
        union() {
            translate([-w/2,bagR,bagR+slotH]) infill(w);
            roundVol(-w/2,w/2,-tabD-rnd,0,-fl-rnd,rackH,rnd);
            volume(-slotW/2,slotW/2,-10,bagR,-10,slotH);  
        }
        volume(-100,100,-100,10,-100,-fl);
        volume(-100,100,-100,-tabD,-100,100);
        latchHole();
        arch();
        leftarch();
        //slot();
    }
}
module plusIns(yVal)  {
    translate([oW/2-footR,yVal,-fl-10+2])
        insertHole(10);
}
module minusIns(yVal)  {
    mirror([1,0,0]) plusIns(yVal);
}
module inserts(yVal) {minusIns(yVal);plusIns(yVal); }
module rack()  { //render()
    //legs
    roundMintVol(-oW/2,oW/2,0,tabW,-fl-rnd,2,footR,rnd);
   
roundMintVol(-oW/2,oW/2,(l/2)-(tabW/2),(l/2)+(tabW/2),-fl-rnd,2,footR,rnd);
    roundMintVol(-oW/2,oW/2,l-tabW,l,-fl-rnd,2,footR,rnd);
    difference()   {        
        union() {
            //main body
            roundMintVol(-w/2,w/2,-20,l,-fl-rnd,8.5,footR,rnd*2);
             
        }  
         
        //volume(-100,100,-10,200,-20,-5);
        volume(-100,100,-25,-latchD,-20,20);
       
       
        //mintVol(-slotMin/2,slotMin/2,tabW,80,-10,10,10);
        volume(-slotMin/2,slotMin/2,0,l,-10,10);
       
       
    }
}

module envelope() {
   
     pommel();
     rack();    
}


module unit()  {
    difference()  {      
        envelope();
        volume(-100,100,-10,250,-100,-fl);
        inserts(footR);inserts(l-footR);inserts(l/2);
        slot();
    }  
}

//scale([25.4,25.4,25.4]) {  //to mm      
    $fn = 64;  //render()
           unit();
           //pommel();
           //plusInsert(0);
           //translate([100,0,-slotH]) rotate([90,0,180])
import("mtx_mount_6.stl");
           //translate([0,.5,.75]) unit();
           //}    
    //$fn = 16; render() unit();
//}

//////////////////////////////////////////UTILITIES.SCAD///////////////////////////////
mm=25.4;
$fn=16;

module mintBox(length,width,height,rad) {
    hull()  {
        translate([rad,rad,0]) cylinder(r=rad,h=height);
        translate([length-rad,rad,0]) cylinder(r=rad,h=height);
        translate([rad,width-rad,0]) cylinder(r=rad,h=height);
        translate([length-rad,width-rad,0]) cylinder(r=rad,h=height);
    }
}
module donut(radius,thickness,x,y,z)  {
    total = thickness+radius; //larger than either!
    translate([x,y,z+thickness/2])
    rotate_extrude()
        intersection()  {
            translate([radius-thickness/2,0,0])
                circle(r = thickness/2);
            translate([0,-total]) square(total*2);
        }
}
module mouth(rad,h) {
    intersection()  {
        donut(rad+h,h*2,0,0,-h);  
        cylinder(h=5,r=rad);  
    }
}
module quartermouth(rad,h)  {
    intersection()  {
        mouth(rad,h);
        volume(0,rad,0,rad,0,h);
    }  
}
module quarterCyl(rad,h) {
    intersection() {
        cylinder(h=h,r=rad);
        volume(0,rad,0,rad,0,l);
    }

}
module fillet(rad,h)  {
    difference() {
        volume(0,rad,0,rad,0,h);
        cylinder(h=h,r=rad);
    }
}
module mintFillet(rad,h,w,d)  {  
    // width and depth are exterior.  Interior is minus height...
    //corners
    translate([w-rad,d-rad,0]) quartermouth(rad,h);
    translate([rad,d-rad,0]) rotate([0,0,90]) quartermouth(rad,h);
    translate([w-rad,rad,0]) rotate([0,0,-90]) quartermouth(rad,h);
    translate([rad,rad,0]) rotate([0,0,180]) quartermouth(rad,h);
    //edges
    translate([0,d-rad,0]) rotate([90,0,0]) quarterCyl(h,d-rad-rad);
    translate([w,d-rad,0]) rotate([90,-90,0]) quarterCyl(h,d-rad-rad);
    translate([rad,0,0]) rotate([90,0,90]) quarterCyl(h,w-rad-rad);
    translate([w-rad,d,0]) rotate([90,0,-90]) quarterCyl(h,w-rad-rad);
}
module roundTube(height,radius,wallTh,x,y,z)  {
    donut(radius,wallTh,x,y,z);
    donut(radius,wallTh,x,y,z+height-wallTh);
    difference()  {
        translate([x,y,wallTh/2+z]) cylinder(r=radius,h=height-wallTh);
        translate([x,y,wallTh/2+z])
cylinder(r=radius-wallTh,h=height-wallTh);
    }
}
module pillar(rad,height,rnd)  {
    difference() {
        cylinder(r=rad+rnd,h=height);
        roundTube(height,rad+rnd+rnd,rnd*2,0,0,0);
    }
}
module quarterPillar(rad,height,rnd)  {
    intersection() {
        volume(0,rad,0,rad,0,height);
        pillar(rad,height,rnd);
    }
}

module pillarFillet(rad,height,rnd) {
    difference() {
        volume(0,rad+rnd,0,rad+rnd,0,height);
        pillar(rad,height,rnd);
    }
}
module roundedCube(x,y,z,rad)  {
     hull()  {
         translate([rad,rad,rad]) sphere(rad);
         translate([x-rad,rad,rad]) sphere(rad);
         translate([x-rad,y-rad,rad]) sphere(rad);
         translate([rad,y-rad,rad]) sphere(rad);
         translate([rad,rad,z-rad]) sphere(rad);
         translate([x-rad,rad,z-rad]) sphere(rad);
         translate([x-rad,y-rad,z-rad]) sphere(rad);
         translate([rad,y-rad,z-rad]) sphere(rad);
     }
}

module pill(radius,thickness,x,y,z)  {
    hull() { donut(radius,thickness,x,y,z); }
}
module quarterPill(radius,thickness)  {
    intersection() {
        vol(0,radius,0,radius,0,thickness);
        pill(radius,thickness,0,0,0);
    }
}
   
module mintVol(xmin,xmax,ymin,ymax,zmin,zmax,rad) {
    hull()  {
        translate([xmin+rad,ymin+rad,zmin]) cylinder(r=rad,h=zmax-zmin);
        translate([xmax-rad,ymax-rad,zmin]) cylinder(r=rad,h=zmax-zmin);
        translate([xmin+rad,ymax-rad,zmin]) cylinder(r=rad,h=zmax-zmin);
        translate([xmax-rad,ymin+rad,zmin]) cylinder(r=rad,h=zmax-zmin);
    }  
   
}
module roundMintVol(xmin,xmax,ymin,ymax,zmin,zmax,rmax,rmin) {
    hull()  {
        donut(rmax,rmin,xmin+rmax,ymin+rmax,zmin);
        donut(rmax,rmin,xmax-rmax,ymax-rmax,zmin);
        donut(rmax,rmin,xmin+rmax,ymax-rmax,zmin);
        donut(rmax,rmin,xmax-rmax,ymin+rmax,zmin);
        donut(rmax,rmin,xmin+rmax,ymin+rmax,zmax-rmin);
        donut(rmax,rmin,xmax-rmax,ymax-rmax,zmax-rmin);
        donut(rmax,rmin,xmin+rmax,ymax-rmax,zmax-rmin);
        donut(rmax,rmin,xmax-rmax,ymin+rmax,zmax-rmin);
    }      
}
module roundVol(xmin,xmax,ymin,ymax,zmin,zmax,rad) {
    hull()  {
        translate([xmin+rad,ymin+rad,zmin+rad]) sphere(r=rad);
        translate([xmax-rad,ymax-rad,zmin+rad]) sphere(r=rad);
        translate([xmin+rad,ymax-rad,zmin+rad]) sphere(r=rad);
        translate([xmax-rad,ymin+rad,zmin+rad]) sphere(r=rad);
        translate([xmin+rad,ymin+rad,zmax-rad]) sphere(r=rad);
        translate([xmax-rad,ymax-rad,zmax-rad]) sphere(r=rad);
        translate([xmin+rad,ymax-rad,zmax-rad]) sphere(r=rad);
        translate([xmax-rad,ymin+rad,zmax-rad]) sphere(r=rad);
    }
}
module volume(x,xTop,y,yTop,z,zTop) {
    box(x,xTop-x,y,yTop-y,z,zTop-z);
}

module box(a,x,b,y,c,z) {
    translate([a,b,c]) cube([x,y,z]);
}

module roundCyl(rad,height,rnd) {
    hull() {
        pill(rad,rnd*2,0,0,0);
        pill(rad,rnd*2,0,0,height-rnd-rnd);
    }  
}
module quarterRoundCyl(rad,height,rnd){
    intersection() {
        volume(0,rad,0,rad,0,height);
        roundCyl(rad,height,rnd);
    }  
}
module invQuarterRoundCyl(rad,height,rnd){
    difference() {
        volume(0,rad,0,rad,0,height);
        roundCyl(rad,height,rnd);
    }  
}

   

module ring(iD,oD,height,rnd)  {
    diam=(oD-iD)/2;
    difference()  {
        translate([0,0,rnd/2]) cylinder(r=oD,h=height);
        translate([0,0,rnd/2]) cylinder(r1=largeR,r2=smallR,h=height);
    }
    donut(diam,rnd,0,0,0);
    donut(diam,rnd,0,0,height);
}

module teensy()  {
    x=35.56;y=17.78;z=1.57;//circuit board
    usbY=8.06;usbI=(y-usbY)/2;//usb jack
    scale([1/mm,1/mm,1/mm]) translate([-x/2,-y/2,-z/2]) color([.3,.5,.3])  {
        cube([x,y,z]);  
        volume(-.06,5,usbI,usbI+usbY,z,z+2.5);
    }
}
module breadboard()  {
    cube([3.22,2.02,.08]);
}

module flatheadHole(length,shaftRad,headRad,headTh,recess) {  
    translate([0,0,-length-.001]) cylinder(r=shaftRad,h=length+.002);
    //for flathead
    translate([0,0,.001-headTh]) cylinder(r1=shaftRad,r2=headRad,h=headTh);
    translate([0,0,0]) cylinder(r=headRad,h=recess);
}
module insert(scrLength,insH,coneR1,coneR2,scr) {
    union() {
        translate([0,0,-.01]) cylinder(r=scr,h=scrLength+.02);
        translate([0,0,scrLength])
           // cylinder($fn=6,r=hexR,h=hexLength);
           cylinder(d1=coneR1,d2=coneR2,h=insH);
    }
}

module insertHole(xpos,ypos,zpos)  {
    top=.25;bottom=.21;height=.312;sR=.084;
    translate([xpos,ypos,zpos-height]) cylinder(d1=bottom,d2=top,h=height);
    translate([xpos,ypos,-1]) cylinder(r=sR,h=zpos+1);
}
module sm58() color([.3,0,.7])  {
    rimD=2.01;  //diameter
    ballD=1.925;
    rimH=.18;
    handleD=1.33;  //diameter
    handleH=.24;
    collarH=.21;
    collarD=1.525;
    rimToTube=1.145;//bottom of tube to center of rim
    intersection()  {
        sphere(d=ballD);
        volume(-2,2,-2,2,-rimToTube,2);
    }
    translate([0,0,-rimH/2]) cylinder(d=rimD,h=rimH);
    translate([0,0,-rimToTube-.75]) cylinder(d=handleD,h=handleH+.75);  
//handle
    translate([0,0,-rimToTube+handleH])
cylinder(d1=handleD,d2=collarD,h=collarH);//collar
    translate([0,0,-rimToTube+handleH+collarH])
cylinder(d=collarD,h=.5);//collar smoother
}

//tests
module mintFilletTest()  {
    x=50;y=18;rad=2;
    mintFillet(rad,1.6,x,y);
    mintVol(0,x,0,y,-3,0,rad);
}
module mouthTest()  {
    quartermouth(4,1);
}
module filletTest(){
    fillet(1,4);
}
module pillarTest() {
    pillarFillet(16,100,3);
}
//render() quarterPillar(5,10,3);
//render() pillarTest();
//filletTest();
//mouthTest();

[/code]



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If it helps, the same main file using this (slightly modified) version of
utlities.scad fails silently without giving any error at all....

utils.scad <http://forum.openscad.org/file/t2632/utils.scad>  



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Did some more sleuthing....

I found it will render module pommel() or module rack(), BUT NOT BOTH!

I tried encosing them in a union, in case that mattered, but it doesn't
help....

I tried moving pommel() inside rack(), but that doesn't help either.

I tried rendering both modules before unioning them, that didn't help.

I should mention I'm using 2019.05 under win10 64.

Frustrating that it doesn't indicate what in my code caused the error.

Here's the latest trace:
Loaded design 'C:/Users/emoon/Documents/Drawings/OPENSCAD/topeakRack.scad'.
Compiling design (CSG Tree generation)...
Compiling design (CSG Products generation)...
ERROR: CGAL error in CGALUtils::applyBinaryOperator union: CGAL ERROR:
assertion violation! Expr: itl != it->second.end() File:
/mxe/usr/x86_64-w64-mingw32.static.posix/include/CGAL/Nef_3/SNC_external_structure.h
Line: 1152
Geometries in cache: 146
Geometry cache size in bytes: 33118200
CGAL Polyhedrons in cache: 8
CGAL cache size in bytes: 85562872
Compiling design (CSG Products normalization)...
Normalized CSG tree has 1 elements
Compile and preview finished.
Total rendering time: 0 hours, 1 minutes, 1 seconds



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Thanks for the tip.  I have tried to track it down from there, and got to
this point:

This works:

            rack();
            //translate([-w/2,bagR,bagR+slotH])
            infill(w);


but this doesn't:

            rack();
            translate([-w/2,bagR,bagR+slotH])  infill(w);

How can just moving one of the (all rendering individually without
complaint) parts create a non-manifold???

infill is fine by itself, it's fine with rack, but if I move it it's not?
What do I do??



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Additionally, both the lines

            rack();

and

            translate([-w/2,bagR,bagR+slotH])  infill(w);

can be unioned with a cube without issue.

Full current code attached.... topeakRack.scad
<http://forum.openscad.org/file/t2632/topeakRack.scad>  
woodslanding wrote




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nophead wrote
> Are the two objects touching? If they are, then they can union to form a
> non-manifold. For example two cubes touching on an edge or a corner makes
> a
> non-manifold.

I read around a bit, and just realized this.  What I can't understand is why
virtually every model I've ever designed hasn't had this problem.

I'm sorry, but from an intuitive standpoint that is utterly insane.  Two 1
unit cubes 1 unit apart is not a valid manifold???

So yeah, I moved the bridge piece .00001mm in some random direction and it
compiles.

I'm sure there's some mathmatical reason why this matters.  There's also got
to be some mathmatical way of dealing with the idea that when two objects
share a face, the face goes away.

Anyway, thanks for the help.  I can't believe I've created hundreds of
models without encountering this before!




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Well, that actually didn't fix it.  I had commented out the render line.
I've tried wiggling its position in all 3 dimensions to no effect.

topeakRack.scad <http://forum.openscad.org/file/t2632/topeakRack.scad>  
utils.scad <http://forum.openscad.org/file/t2632/utils.scad>  

I've always gotten a warning about manifolds before, not an incomprehensible
stack trace....


nophead wrote
> Sorry I meant: They can't share just an edge or a single vertex as it
> creates a zero thickness section that isn't physically possible,
>
>
> On Tue, 9 Jun 2020 at 23:48, nop head &lt;

> nop.head@

> &gt; wrote:
>
>> Two cubes can share a face or a part of a face, or they can overlap. They
>> can't share just and edge of a single vertex as it creates a zero
>> thickness
>> section that isn't physically possible,
>>
>> On Tue, 9 Jun 2020 at 23:32, woodslanding &lt;

> temiqui@

> Discuss@.openscad

>>> http://lists.openscad.org/mailman/listinfo/discuss_lists.openscad.org
>>>
>>
>
> _______________________________________________
> OpenSCAD mailing list

> Discuss@.openscad

> http://lists.openscad.org/mailman/listinfo/discuss_lists.openscad.org





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woodslanding wrote
Unfortunately with those two files and

translate([0,0,-30]) cube(1);
rack();
translate([-w/2,bagR,bagR+slotH])  infill(w);

I do not get a CGAL error on F6. Tried 2019.05 & a recent development
version.





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No error, regardless of Lazy-union on/off.



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Figured it out!

It didn't like the render() in the infill() module.  Took that out and it
rendered fine.



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Tim Hawkins wrote
> Would it be feassble to have an auto-manifold fix mode that inflates all
> objects by a very very small amount (but greater than tbe rounding) so
> that
> the 1unit cube example is fixed. It wont help with with things liked
> differenced cylinders,  it it may fix many headscratchers.

When you start looking at the details it is difficult. Your very very small
amount may then butt up against another edge or point.


> Alternativly is it feasible to highlight non-manifold surfaces on the
> display?

see thrown-together
https://en.wikibooks.org/wiki/OpenSCAD_User_Manual/Primitive_Solids#Mis-ordered_faces




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