feat: block unsafe Optimize geometry

Issue: #199
User-Visible: yes

demo/benchmark_optimize_geometry_preflight.mjs

@@ -0,0 +1,96 @@
+// #199: same-process production-builder baseline versus the complete Optimize
+// preflight wrapper on the deterministic 3-floor large-house fixture.
+import { performance } from 'node:perf_hooks';
+
+import { makeLargeHouseFixture, LARGE_HOUSE_COUNTS } from './fixtures/large-house.mjs';
+import {
+  checkOptimizeGeometry,
+  prepareSpacePhysicalGeometryInputs,
+} from '../test-build/plan-geometry-preflight.js';
+import { spaceModels } from '../test-build/space-geometry.js';
+import {
+  floorFootprintGeometry,
+  wallBodiesGeometry,
+} from '../test-build/wall-thickness.js';
+
+const WARMUPS = 3;
+const SAMPLES = 20;
+const ABSOLUTE_P95_MS = 250;
+const RELATIVE_RATIO = 1.2;
+const RELATIVE_NOISE_MS = 15;
+
+const fixture = makeLargeHouseFixture();
+const models = spaceModels(fixture.config);
+const prepared = fixture.config.spaces.map((space, index) =>
+  prepareSpacePhysicalGeometryInputs(space, models[index]));
+
+const directProductionPass = () => {
+  for (const input of prepared) {
+    const hasWalls = input.walls.length > 0 || input.physicalBodies.length > 0;
+    const united = hasWalls
+      ? wallBodiesGeometry(
+          input.space.rooms, input.walls, input.openCuts, input.roomOpenings,
+          input.wallKeyPitch, input.cellCm, input.gridPitch, input.coordScale,
+          input.physicalBodies,
+        )
+      : null;
+    if (hasWalls && united == null) throw new Error(`baseline wall failure: ${input.space.id}`);
+    if (input.space.rooms.length && united?.paperGeom == null) {
+      const floor = floorFootprintGeometry(
+        input.space.rooms, input.walls, input.openCuts,
+        input.wallKeyPitch, input.cellCm, input.gridPitch, input.coordScale,
+      );
+      if (floor == null) throw new Error(`baseline floor failure: ${input.space.id}`);
+    }
+  }
+};
+
+const completePreflight = () => {
+  const result = checkOptimizeGeometry(fixture.config);
+  if (!result.ok || result.spaces.length !== LARGE_HOUSE_COUNTS.floors
+      || result.spaces.some((space) => space.status !== 'ok')) {
+    throw new Error(`candidate preflight failure: ${JSON.stringify(result.spaces)}`);
+  }
+};
+
+const sample = (operation) => {
+  const start = performance.now();
+  operation();
+  return performance.now() - start;
+};
+const run = (operation) => {
+  for (let index = 0; index < WARMUPS; index++) operation();
+  return Array.from({ length: SAMPLES }, () => sample(operation));
+};
+const quantile = (values, ratio) => {
+  const sorted = [...values].sort((a, b) => a - b);
+  return sorted[Math.min(sorted.length - 1, Math.ceil(sorted.length * ratio) - 1)];
+};
+const summary = (values) => ({
+  min: Math.min(...values),
+  median: quantile(values, 0.5),
+  p95: quantile(values, 0.95),
+  max: Math.max(...values),
+});
+
+const baseline = summary(run(directProductionPass));
+const candidate = summary(run(completePreflight));
+const relativeLimit = baseline.p95 * RELATIVE_RATIO + RELATIVE_NOISE_MS;
+const pass = candidate.p95 <= ABSOLUTE_P95_MS && candidate.p95 <= relativeLimit;
+const report = {
+  issue: 199,
+  fixture: LARGE_HOUSE_COUNTS,
+  warmups: WARMUPS,
+  samples: SAMPLES,
+  baseline,
+  candidate,
+  budgets: {
+    absoluteP95Ms: ABSOLUTE_P95_MS,
+    relativeRatio: RELATIVE_RATIO,
+    relativeNoiseMs: RELATIVE_NOISE_MS,
+    relativeLimitP95Ms: relativeLimit,
+  },
+  pass,
+};
+console.log(JSON.stringify(report, null, 2));
+if (!pass) process.exitCode = 1;

demo/golden/harness.mjs

@@ -599,7 +599,36 @@ export async function prepareGoldenScenario(page, scenario) {
       card.requestUpdate();
       await card.updateComplete;
     }
-    if (scenario.dialog === 'device') {
+    if (scenario.dialog === 'optimize-preflight') {
+      const names = [
+        'Ground floor', 'Garage', card._t('gs.align_preflight_space', { n: '3' }), 'Attic',
+      ];
+      const failures = names.map((displayName, index) => ({
+        spaceId: `golden-failure-${index + 1}`,
+        displayName,
+        status: 'failed',
+        reason: 'wall-null',
+      }));
+      card._alignDialog = {
+        report: {}, config: card._serverCfg, layout: card._layout,
+        preflight: {
+          fingerprint: 'golden-optimize-preflight',
+          spaces: failures,
+          failures,
+          ok: false,
+        },
+        cm: 0, where: '', changed: true, busy: false,
+      };
+      card.requestUpdate();
+      await card.updateComplete;
+      const dialog = card.renderRoot.querySelector('hp-dialog');
+      const body = dialog?.querySelector('.body');
+      if (!body?.textContent?.includes(names[0])
+          || !body.textContent.includes(card._t('gs.align_preflight_hint'))
+          || dialog.querySelector('.btn.on')) {
+        throw new Error('golden Optimize preflight failure dialog is incomplete');
+      }
+    } else if (scenario.dialog === 'device') {
       card._setMode('devices');
       await card.updateComplete;
       await settleMode(card);

demo/golden/matrix.mjs

@@ -1,7 +1,7 @@
 import { fixtureWallKey } from '../fixtures/visual-matrix.mjs';
 
 /** Data-only HP-QA-01 capture matrix. Bump when framing or scenarios change. */
-export const GOLDEN_MATRIX_VERSION = 33;
+export const GOLDEN_MATRIX_VERSION = 34;
 
 const stage = { capture: 'stage', threshold: { maxChannelDelta: 10, maxDiffRatio: 0.0005 } };
 const page = { capture: 'page', threshold: { maxChannelDelta: 10, maxDiffRatio: 0.0008 } };
@@ -382,4 +382,10 @@ export const GOLDEN_SCENARIOS = Object.freeze([
   { id: 'backup-space-preview-mobile-ru', fixture: 'visual', space: 'golden-geometry',
     dialog: 'backup-space', language: 'ru', theme: 'light',
     viewport: { width: 390, height: 820 }, ...page },
+  { id: 'optimize-preflight-dialog-dark-en', fixture: 'visual', space: 'golden-geometry',
+    dialog: 'optimize-preflight', language: 'en', theme: 'dark',
+    viewport: { width: 900, height: 760 }, ...page },
+  { id: 'optimize-preflight-dialog-light-ru', fixture: 'visual', space: 'golden-geometry',
+    dialog: 'optimize-preflight', language: 'ru', theme: 'light',
+    viewport: { width: 900, height: 760 }, ...page },
 ]);

demo/smoke_optimize_geometry_preflight.mjs

@@ -0,0 +1,152 @@
+// #199: the production bundle must fail closed before the Optimize WS write,
+// keep one exact-candidate preflight result, and preserve the existing green
+// Preview → Apply / no-op contract.
+import { launch, checkAll, finish } from './serve.mjs';
+
+const { page, browser } = await launch({ width: 920, height: 840 });
+const out = await page.evaluate(async () => {
+  const result = {};
+  const card = window.__card;
+  const clone = (value) => structuredClone(value);
+  const noisy = [[
+    [0.10000000000000002, 0.1], [0.9, 0.1], [0.9, 0.9], [0.1, 0.9],
+  ]];
+  const makeSpace = (id, title) => ({
+    id, title, view_box: [0, 0, 1, 1], cell_cm: 5,
+    rooms: noisy.map((poly, index) => ({ id: `room-${id || index}`, poly })),
+  });
+  const original = {
+    model_version: 6,
+    spaces: [
+      makeSpace('alpha', 'Alpha'),
+      makeSpace('beta', ''),
+      makeSpace('', ''),
+      makeSpace('unsafe', '<img id="preflight-injection" src=x>'),
+    ],
+    markers: [], settings: {},
+  };
+  const originalLayout = { marker: { s: 'alpha', x: 0.2, y: 0.2 } };
+  const baseCall = card.hass.callWS.bind(card.hass);
+  const sent = [];
+  card.hass = {
+    ...card.hass,
+    callWS: async (message) => {
+      if (message.type === 'houseplan/plan/optimize') {
+        sent.push(clone(message));
+        return { ok: true, config_rev: 42, layout_rev: 24, can_undo: true };
+      }
+      return baseCall(message);
+    },
+  };
+  const setCandidate = (language = 'en') => {
+    card._config = { ...card._config, language };
+    card._serverCfg = clone(original);
+    card._layout = clone(originalLayout);
+    card._cfgRev = 10;
+    card._layoutRev = 11;
+    card._canOptimizeUndo = false;
+    card._undoKind = null;
+    card._modelCache = null;
+    card._frame = null;
+    card._space = 'alpha';
+  };
+  const originalCheck = card._checkOptimizeGeometry.bind(card);
+  let checks = 0;
+  let forceRed = true;
+  card._checkOptimizeGeometry = (config) => {
+    checks++;
+    const checked = originalCheck(config);
+    if (!forceRed) return checked;
+    const failures = checked.spaces.map((space) => ({
+      ...space, status: 'failed', reason: 'wall-null',
+    }));
+    return { ...checked, spaces: failures, failures, ok: false };
+  };
+
+  setCandidate('en');
+  const beforeRed = {
+    config: clone(card._serverCfg), layout: clone(card._layout),
+    configRev: card._cfgRev, layoutRev: card._layoutRev,
+    canUndo: card._canOptimizeUndo, undoKind: card._undoKind,
+  };
+  card._openAlignDialog(); await card.updateComplete;
+  const englishText = card.renderRoot.querySelector('hp-dialog .body')?.textContent || '';
+  result.englishFailureNamesThreeAndCountsRest = englishText.includes(
+    'Could not safely verify the geometry of the following spaces: Alpha, beta, Space 3, and 1 more.',
+  );
+  result.englishFailureHasExactHint = englishText.includes(
+    'Plans were not changed. Update House Plan and try again. If the error persists, attach a space export to the bug report.',
+  );
+  result.failureTitleIsEscapedAndFourthNameHidden =
+    !card.renderRoot.querySelector('#preflight-injection')
+    && !englishText.includes('<img') && !englishText.includes('unsafe');
+  result.failureRendersNoApply = !card.renderRoot.querySelector('hp-dialog .btn.on');
+  await card._runAlignToGrid(); await card.updateComplete;
+  result.redPreflightMakesZeroWrites = sent.length === 0;
+  result.redPreflightPreservesAllState =
+    JSON.stringify(card._serverCfg) === JSON.stringify(beforeRed.config)
+    && JSON.stringify(card._layout) === JSON.stringify(beforeRed.layout)
+    && card._cfgRev === beforeRed.configRev && card._layoutRev === beforeRed.layoutRev
+    && card._canOptimizeUndo === beforeRed.canUndo && card._undoKind === beforeRed.undoKind;
+
+  // A green preview whose exact candidate changes must be checked again. A
+  // newly red result replaces the dialog and still cannot write.
+  forceRed = false;
+  setCandidate('en');
+  card._openAlignDialog(); await card.updateComplete;
+  const checksAfterGreenPreview = checks;
+  result.greenPreviewOffersApply = !!card.renderRoot.querySelector('hp-dialog .btn.on');
+  card._alignDialog.config.spaces[0].title = 'Changed after preview';
+  forceRed = true;
+  await card._runAlignToGrid(); await card.updateComplete;
+  result.changedFingerprintRechecks = checks === checksAfterGreenPreview + 1;
+  result.changedFingerprintFailsClosed = sent.length === 0
+    && !card._alignDialog.preflight.ok
+    && !card.renderRoot.querySelector('hp-dialog .btn.on');
+
+  // An unchanged green candidate reuses the preview result, performs exactly
+  // one existing atomic endpoint call, and keeps the existing Undo contract.
+  forceRed = false;
+  setCandidate('en');
+  const callsBeforeGreen = sent.length;
+  card._openAlignDialog(); await card.updateComplete;
+  const checksBeforeApply = checks;
+  const previewCandidate = clone(card._alignDialog.config);
+  await card._runAlignToGrid(); await card.updateComplete;
+  result.unchangedApplyDoesNotRecheck = checks === checksBeforeApply;
+  result.greenApplyMakesOneAtomicWrite = sent.length === callsBeforeGreen + 1
+    && JSON.stringify(sent.at(-1).config) === JSON.stringify(previewCandidate);
+  result.greenApplyPreservesUndoContract = card._canOptimizeUndo === true
+    && card._undoKind === 'optimize' && card._cfgRev === 42 && card._layoutRev === 24;
+
+  // The just-written candidate is now a no-op: it skips the geometry pass and
+  // retains the established message/absence of Apply.
+  const checksBeforeNoOp = checks;
+  card._openAlignDialog(); await card.updateComplete;
+  const noOpText = card.renderRoot.querySelector('hp-dialog .body')?.textContent || '';
+  result.noOpSkipsPreflight = checks === checksBeforeNoOp
+    && card._alignDialog.preflight === null;
+  result.noOpKeepsExistingUi = noOpText.includes(
+    'All plans already use the current optimized data model.',
+  ) && !card.renderRoot.querySelector('hp-dialog .btn.on');
+  card._alignDialog = null; await card.updateComplete;
+
+  // The same bounded copy and fallback/count policy is localized in Russian.
+  forceRed = true;
+  setCandidate('ru');
+  card._openAlignDialog(); await card.updateComplete;
+  const russianText = card.renderRoot.querySelector('hp-dialog .body')?.textContent || '';
+  result.russianFailureHasExactCopy = russianText.includes(
+    'Не удалось безопасно проверить геометрию следующих пространств: Alpha, beta, Пространство 3 и ещё 1.',
+  ) && russianText.includes(
+    'Планы не изменены. Обновите House Plan и повторите. Если ошибка останется, приложите экспорт пространства к отчёту об ошибке.',
+  );
+  card.renderRoot.querySelector('hp-dialog')?.dispatchEvent(new CustomEvent(
+    'hp-close', { bubbles: true, composed: true },
+  ));
+  await card.updateComplete;
+  result.failureCloseDoesNotWrite = card._alignDialog === null && sent.length === callsBeforeGreen + 1;
+  return result;
+});
+
+await finish(browser, checkAll(out));

docs/ARCHITECTURE.md

@@ -658,6 +658,17 @@ gaps.
 | `houseplan/import/revalidate` | preview `token`, `duplicate_policy?` | refreshed bounded preview and current expected revisions |
 | `houseplan/import/apply` | token, both expected revisions, content confirmation | crash-resumable paired config/layout commit; full import gets one-deep undo |
 
+The normal frontend reaches `houseplan/plan/optimize` only after the exact
+preview candidate passes `src/plan-geometry-preflight.ts`. That pure barrier
+uses the same room/open-span/ordinary+hosted-opening projection,
+`physicalBodyParts`, `wallBodiesGeometry` and `floorFootprintGeometry` as the
+renderer for every space. The dialog retains statuses and a config fingerprint,
+not polygon output or exception text; a mismatch before Apply triggers a fresh
+check. A red result means zero WS calls. Python deliberately does not duplicate
+`polyclip-ts`: the endpoint remains the independent permission/schema/revision
+and crash-resumable atomicity boundary, not a consumer-supplied preflight
+attestation.
+
 Manual attachments upload over HTTP (streaming, transactional staging), not WS —
 the old `houseplan/file/set` was removed in v1.10.0.
 

docs/CANVAS.md

@@ -524,6 +524,18 @@ idempotence case in `test/plan-optimizer.test.mjs`:
   `coordsCanonicalized: 0`, and returns objects deep-equal to the first run's;
 * the report is an **upper bound**, not a sample (AUD-158B1-01).
 
+Before a changed preview can expose Apply, `checkOptimizeGeometry(config)`
+(`src/plan-geometry-preflight.ts`) runs the exact candidate through the shared
+production input projection and canonical wall/floor boolean builders for every
+space. `null` or an exception is a structural failure; an empty successful
+geometry and an empty/image-only space are not. One failure blocks the whole
+operation and the endpoint is not called. The dialog retains only bounded
+statuses plus `contentFingerprint(candidate.config)`: unchanged Apply reuses
+that result, while a changed fingerprint is checked again and fails closed.
+This frontend barrier does not replace backend permission, schema, revision or
+crash-recovery checks and is not a security attestation from an untrusted
+client.
+
 ### The report is a promise
 
 The confirmation is the decision gate in front of a geometry rewrite, so

docs/CHANGELOG.md

@@ -2,6 +2,13 @@
 
 ## Unreleased
 
+- “Optimize plans” now verifies the exact preview candidate with the same wall,
+  opening, partition, column and floor geometry builders used by the card. If
+  any space cannot be built safely, the preview names up to three affected
+  spaces, explains how to report the problem and offers only Cancel: config,
+  layout, revisions and the one-deep Undo snapshot remain untouched
+  ([#199](https://github.com/Matysh/houseplan-card/issues/199)).
+
 - Every config and device-layout write now canonicalizes persisted geometry to
   nine decimal places without snapping it to the grid. This removes invisible
   floating-point tails before they can break shared walls, room unions or Glow;

docs/CHANGELOG.ru.md

@@ -8,6 +8,14 @@
 
 ## Не выпущено
 
+- «Оптимизировать планы» теперь проверяет точный кандидат из предпросмотра теми
+  же построителями стен, проёмов, перегородок, колонн и пола, которыми пользуется
+  карточка. Если геометрию хотя бы одного пространства нельзя безопасно
+  построить, диалог называет до трёх проблемных пространств, объясняет, как
+  сообщить об ошибке, и оставляет только «Отмена»: конфигурация, раскладка,
+  ревизии и одношаговая отмена не меняются
+  ([#199](https://github.com/Matysh/houseplan-card/issues/199)).
+
 - Каждая запись конфигурации и раскладки устройств теперь приводит геометрию к
   девяти десятичным знакам, не привязывая её к сетке. Невидимые
   floating-point-хвосты удаляются до того, как смогут сломать общие стены,

docs/STATUS.md

@@ -22,7 +22,7 @@ metadata). Only an explicit owner-approved emergency hotfix may skip this gate.
 | Item | State |
 |---|---|
 | Version | **v1.66.0** everywhere (manifest, const.py, package.json, CARD_VERSION) — stable promotion of the published v1.66.0-beta.1 product line |
-| Current local cycle | Post-v1.66.0 Unreleased development includes reliable Plan drawing (#228): exact Shift rays, ambiguous-node blocking, active axis/node chrome, room creation from an existing face with an explicit ≤2 cm repair, and room deletion with Keep/Delete walls consequences. Entity/parent marker deduplication (#226), explicit coordinate maintenance (#223) and canonical geometry on every write (#224) are also included. |
+| Current local cycle | Post-v1.66.0 Unreleased development includes reliable Plan drawing (#228): exact Shift rays, ambiguous-node blocking, active axis/node chrome, room creation from an existing face with an explicit ≤2 cm repair, and room deletion with Keep/Delete walls consequences. Entity/parent marker deduplication (#226), explicit coordinate maintenance (#223), canonical geometry on every write (#224) and a fail-closed production-geometry preflight for the exact Optimize candidate (#199) are also included. |
 | Hidden Labs Stage | #89 Stage 1 ships in v1.63.0-beta.1. #122 Stage 2 ships in v1.64.0 and evolves the same hidden, expiring `iso` experiment with matte walls, a low exterior floor edge, restrained shared shadows and live vertical door/window/gate panels. Flat remains default; editors and `houseplan-space-card` remain flat; live floor effects and HA actions remain unchanged. Public activation remains a separate task. |
 | Workflow | Superseded 2026-08-12: the pre-1.62 rule of "local edits without tests or commits" is **dead** — since release 1.62 every product change follows `PROCESS.md` (issue in `S5-ready`+, branch `issue/<NN>-slug`, trailers on every commit, review pipeline; `AGENTS.md` is the summary). Release mechanics below remain current. A requested pre-release gets a production build plus the smallest targeted unit/smoke set covering the changed surfaces, one tested `dev` commit/tag and a GitHub Release with `prerelease=true`; `main` stays untouched. The complete local frontend/backend/smoke gate runs only before a stable release, after which `main` is fast-forwarded to the exact tested `dev` SHA and the GitHub Release uses `prerelease=false`. Release bodies are short and bilingual (Russian first): only significant user changes get individual bullets, while minor/code-only work is grouped as `Мелкие исправления и улучшения` / `Small fixes and improvements`; every body ends with separate links to the Russian and English changelogs. Detailed RU/EN changelog bullets may link the corresponding closed GitHub Issues; open or partially delivered issues are never presented as shipped. Telegram announcements are sent only for stable releases; beta and RC publication is silent. `docs/RELEASE-NOTES.md` is the current canonical body instance; `npm run release:prerelease -- <tag> --issues=… --yes` is the primary local publication path and the manual `Publish prerelease` workflow is its GitHub-only equivalent once present on `main`. Nothing is copied to the home instance by hand |
 | GitHub | https://github.com/Matysh/houseplan-card — [Issues](https://github.com/Matysh/houseplan-card/issues) are the canonical task records; their labels carry priority and workflow status (`PROCESS.md` §9). GitHub Projects is no longer used. `main` carries stable releases; pre-release tags may point directly at `dev`. Work lands on `dev` and is merged into `main` for a stable release, so `dev` is normally equal to or ahead of `main`, never behind. Push via SSH key `ha_jb` (remote git@github.com:…); API releases via the fine-grained PAT in `~/.git-credentials` (Contents R/W, issued 2026-07-23) |

docs/TESTING.md

@@ -2096,6 +2096,23 @@ require hands on real hardware — they remain for the human pass.
       [unit: align-grid + plan-optimizer + i18n; auto:
       smoke_optimize_coordinate_canonicalization; mutation:
       `snapn-returns-input-near-node`].
+- [ ] **Optimize rejects an unrenderable candidate before writing (#199)**:
+      all spaces pass the shared production wall/opening/physical/floor input
+      projection. A forced wall/floor `null` or exception produces only a
+      bounded failure code; valid empty/image-only spaces remain allowed. One
+      failing floor removes Apply and makes zero Optimize WS calls without
+      changing config, layout, revisions or Undo. The first three safe names,
+      the remaining count and recovery hint are exact in RU/EN; unchanged Apply
+      reuses its fingerprint result, while a changed candidate is checked again.
+      The 3-floor/60-room/100-opening/60-partition/40-column fixture must stay
+      under 250 ms p95 and within direct-builder p95 × 1.2 + 15 ms
+      [unit: test/plan-geometry-preflight.test.mjs; auto:
+      smoke_optimize_geometry_preflight; benchmark:
+      benchmark_optimize_geometry_preflight; golden: dark/light failure dialog;
+      mutations: `optimize-preflight-bypassed`,
+      `optimize-preflight-active-space-only`,
+      `optimize-preflight-accepts-null`,
+      `optimize-preflight-renders-apply-on-failure`].
 - [ ] **Every write prevents new ULP coordinate noise (#224)**: config/layout
       schema, import, direct storage writers, startup recovery and maintenance
       Undo produce the same nine-decimal allow-listed geometry as the frontend.

docs/USER-GUIDE.ru.md

@@ -1366,6 +1366,15 @@ show_signal: true
 честный предпросмотр «сдвинуто элементов — 0» с ненулевым числом очищенных
 координат. Повторный Optimize над результатом ничего не предлагает.
 
+Перед подтверждением House Plan дополнительно строит точную геометрию кандидата
+для **всех** пространств — тем же способом, которым затем рисуются стены,
+проёмы, перегородки, колонны и пол. Если проверка хотя бы одного пространства
+не прошла, оптимизация целиком блокируется: вместо отчёта диалог называет до
+трёх пространств и количество остальных, а кнопки «Оптимизировать» нет.
+Конфигурация, позиции, ревизии и доступная серверная отмена при этом не
+изменяются. Обновите House Plan и повторите; если сообщение осталось, приложите
+экспорт названного пространства к отчёту об ошибке.
+
 ### Что оптимизация сохраняет
 
 - неизвестные поля новых версий;

docs/images/screenshots.json

@@ -1,7 +1,7 @@
 {
   "version": 1,
   "fixture": "synthetic-only",
-  "sourceFingerprint": "ef5431f42e2c08425388d4d14df10de29040ea755ac64f81b734430729faae4f",
+  "sourceFingerprint": "967bdb37e447ec29a88d82707f5ff957e576be72fbe801445c6cbdec970e43eb",
   "captureScriptSha256": "34f2219790d46efd8250e7a1bd829cb8fc0b0547e1260635fefa52407551b41b",
   "command": "npm run build && node demo/docs/capture.mjs",
   "scenarios": {
@@ -13,7 +13,7 @@
       },
       "theme": "dark",
       "language": "en",
-      "sourceSha256": "ef5431f42e2c08425388d4d14df10de29040ea755ac64f81b734430729faae4f",
+      "sourceSha256": "967bdb37e447ec29a88d82707f5ff957e576be72fbe801445c6cbdec970e43eb",
       "imageSha256": "2885f96e348b15ab7c696e56e99bddcd9bb2ee94218a883e5a2155f45f5042aa"
     },
     "view-touch": {
@@ -24,7 +24,7 @@
       },
       "theme": "dark",
       "language": "en",
-      "sourceSha256": "ef5431f42e2c08425388d4d14df10de29040ea755ac64f81b734430729faae4f",
+      "sourceSha256": "967bdb37e447ec29a88d82707f5ff957e576be72fbe801445c6cbdec970e43eb",
       "imageSha256": "f62d8af3617c00a5e99511bd765980d2e27badf25047a1be34046b64195abe6c"
     },
     "space-create": {
@@ -35,7 +35,7 @@
       },
       "theme": "dark",
       "language": "en",
-      "sourceSha256": "ef5431f42e2c08425388d4d14df10de29040ea755ac64f81b734430729faae4f",
+      "sourceSha256": "967bdb37e447ec29a88d82707f5ff957e576be72fbe801445c6cbdec970e43eb",
       "imageSha256": "c33a7279165a4cec6fa6fadb6fd08cd967e082a17fe101ef442d27d36ae59b6b"
     },
     "room-contour-close": {
@@ -46,7 +46,7 @@
       },
       "theme": "dark",
       "language": "en",
-      "sourceSha256": "ef5431f42e2c08425388d4d14df10de29040ea755ac64f81b734430729faae4f",
+      "sourceSha256": "967bdb37e447ec29a88d82707f5ff957e576be72fbe801445c6cbdec970e43eb",
       "imageSha256": "4d63670c7bcca33da21a6cf17275786bed12e8422a50d02d4dabe59645f2cd82"
     },
     "plan-context-tray": {
@@ -57,7 +57,7 @@
       },
       "theme": "dark",
       "language": "en",
-      "sourceSha256": "ef5431f42e2c08425388d4d14df10de29040ea755ac64f81b734430729faae4f",
+      "sourceSha256": "967bdb37e447ec29a88d82707f5ff957e576be72fbe801445c6cbdec970e43eb",
       "imageSha256": "a6c526fede11bc3503fd2384bd4a3f6afa008f481c5c47578f06cae6c81c6f9b"
     },
     "device-editor": {
@@ -68,7 +68,7 @@
       },
       "theme": "dark",
       "language": "en",
-      "sourceSha256": "ef5431f42e2c08425388d4d14df10de29040ea755ac64f81b734430729faae4f",
+      "sourceSha256": "967bdb37e447ec29a88d82707f5ff957e576be72fbe801445c6cbdec970e43eb",
       "imageSha256": "9585b59add4d35b5a6f028ce5b720ef1b77a3f8b19436d192cd1a0e6fc637264"
     },
     "device-display-preview": {
@@ -79,7 +79,7 @@
       },
       "theme": "dark",
       "language": "en",
-      "sourceSha256": "ef5431f42e2c08425388d4d14df10de29040ea755ac64f81b734430729faae4f",
+      "sourceSha256": "967bdb37e447ec29a88d82707f5ff957e576be72fbe801445c6cbdec970e43eb",
       "imageSha256": "cfc317da4628d079a116ff71311fbf06b1eb3b181928a5ea7ba888ab936a5e8b"
     },
     "background-editor": {
@@ -90,7 +90,7 @@
       },
       "theme": "dark",
       "language": "en",
-      "sourceSha256": "ef5431f42e2c08425388d4d14df10de29040ea755ac64f81b734430729faae4f",
+      "sourceSha256": "967bdb37e447ec29a88d82707f5ff957e576be72fbe801445c6cbdec970e43eb",
       "imageSha256": "d7cfe70551d9260169df8efd832e32ed7df99c7f60b55d1fd4a8322bd4c47175"
     },
     "room-card": {
@@ -101,7 +101,7 @@
       },
       "theme": "dark",
       "language": "en",
-      "sourceSha256": "ef5431f42e2c08425388d4d14df10de29040ea755ac64f81b734430729faae4f",
+      "sourceSha256": "967bdb37e447ec29a88d82707f5ff957e576be72fbe801445c6cbdec970e43eb",
       "imageSha256": "029a3e69ec647a8a370d99e6bb7f9225833c526739076022f6b52ba54bff30ea"
     },
     "device-info": {
@@ -112,7 +112,7 @@
       },
       "theme": "dark",
       "language": "en",
-      "sourceSha256": "ef5431f42e2c08425388d4d14df10de29040ea755ac64f81b734430729faae4f",
+      "sourceSha256": "967bdb37e447ec29a88d82707f5ff957e576be72fbe801445c6cbdec970e43eb",
       "imageSha256": "a06cbf83f09e2f67b3566d7c0b10e973db060c3d20786f26f74ada6a21937c3e"
     }
   }

package.json

@@ -16,6 +16,7 @@
     "benchmark:large-house-plan-snap": "node demo/benchmark_large_house.mjs --profile=large-house-plan-snap-v1",
     "benchmark:glow": "node demo/benchmark_glow.mjs",
     "benchmark:compare": "node demo/performance/compare.mjs",
+    "benchmark:optimize-geometry-preflight": "node demo/benchmark_optimize_geometry_preflight.mjs",
     "golden:capture": "node demo/golden/run.mjs --mode=capture",
     "golden:verify": "node demo/golden/run.mjs --mode=verify",
     "continuity:screencast": "node demo/screencast_visual_continuity.mjs",

scripts/mutation-gate.mjs

@@ -229,6 +229,54 @@ export const MUTANTS = [
       replace: '        config = _json_copy(payload.get("config"))',
     }],
   },
+  {
+    id: 'optimize-preflight-bypassed',
+    guard: 'node demo/smoke_optimize_geometry_preflight.mjs',
+    because: 'a red preview must remain a hard write barrier even if a caller invokes the '
+      + 'private Apply method directly instead of clicking the deliberately absent button (#199)',
+    patches: [{
+      file: 'src/houseplan-card.ts',
+      find: '    if (!d || d.busy || !this._serverCfg || !d.changed || !d.preflight?.ok) return;',
+      replace: '    if (!d || d.busy || !this._serverCfg || !d.changed) return;',
+    }],
+  },
+  {
+    id: 'optimize-preflight-active-space-only',
+    guard: 'npx tsc -p tsconfig.test.json && node scripts/fix-test-build.mjs '
+      + '&& node --test --test-name-pattern="one failed space blocks" '
+      + 'test/plan-geometry-preflight.test.mjs',
+    because: 'Optimize is one whole-plan transaction, so a broken non-active floor must block '
+      + 'the operation just as decisively as the first floor in config order (#199)',
+    patches: [{
+      file: 'src/plan-geometry-preflight.ts',
+      find: '  const rawSpaces = Array.isArray(config?.spaces) ? config.spaces : [];',
+      replace: '  const rawSpaces = Array.isArray(config?.spaces) ? config.spaces.slice(0, 1) : [];',
+    }],
+  },
+  {
+    id: 'optimize-preflight-accepts-null',
+    guard: 'npx tsc -p tsconfig.test.json && node scripts/fix-test-build.mjs '
+      + '&& node --test --test-name-pattern="null, exceptions and floor failure" '
+      + 'test/plan-geometry-preflight.test.mjs',
+    because: 'wallBodiesGeometry null is a structural boolean failure, not an empty successful '
+      + 'wall set that may be hidden behind a later floor fallback (#199)',
+    patches: [{
+      file: 'src/plan-geometry-preflight.ts',
+      find: '      if (united == null) {',
+      replace: '      if (false && united == null) {',
+    }],
+  },
+  {
+    id: 'optimize-preflight-renders-apply-on-failure',
+    guard: 'node demo/smoke_optimize_geometry_preflight.mjs',
+    because: 'the failure state is not a dismissible warning: rendering Apply invites a person '
+      + 'to treat an unsafe whole-plan candidate as an accepted risk (#199)',
+    patches: [{
+      file: 'src/houseplan-card.ts',
+      find: '          ${!d.changed || !d.preflight?.ok ? nothing : html`',
+      replace: '          ${!d.changed ? nothing : html`',
+    }],
+  },
   {
     id: 'union-failure-kills-space',
     guard: 'npx tsc -p tsconfig.test.json && node scripts/fix-test-build.mjs '

src/houseplan-card.ts

@@ -149,7 +149,7 @@ import {
 import {
   hostedOpeningIntervalsOverlap, materializePartitionOpening,
   partitionOpeningJambMargin, partitionOpeningNeedsStrictValidation,
-  partitionOpeningCut, partitionOpeningFace, partitionOpeningHasCompositeRoomWall,
+  partitionOpeningFace,
   partitionPlacementIntervals, resolvePartitionOpeningCompat, resolvePartitionOpeningStrict,
   type PartitionOpeningOrphanReason, type ResolvedPartitionOpening,
 } from './partition-openings';
@@ -187,6 +187,16 @@ import {
   clampCanvasR, clampCanvasN, type ContentItem, type Rect,
 } from './space-geometry';
 import { optimizePlans, type OptimizeReport } from './plan-optimizer';
+import {
+  checkOptimizeGeometry,
+  geometryOpenCuts,
+  geometryOpenings,
+  geometryOpenPairs,
+  geometryPartitionOpeningCuts,
+  geometryRoomOpeningInputs,
+  type GeometryOpeningProjection,
+  type OptimizeGeometryPreflightResult,
+} from './plan-geometry-preflight';
 import {
   canonicalizeConfigGeometry,
   canonicalizeLayoutGeometry,
@@ -1707,6 +1717,7 @@ class HouseplanCard extends LitElement {
   /** Optimization preview plus the exact pair, so commit cannot differ from it. */
   private _alignDialog: {
     report: OptimizeReport; config: any; layout: Record<string, any>;
+    preflight: OptimizeGeometryPreflightResult | null;
     /** the promised maximum, in centimetres, ALREADY rounded up (AUD-158B1-01) */
     cm: number;
     /** the space that maximum belongs to, named only when there are several */
@@ -8588,16 +8599,11 @@ class HouseplanCard extends LitElement {
     accept: (opening: OpeningCfg) => boolean = () => true,
   ): PartitionOpeningCut[] {
     if (!space) return [];
-    const raw = this._curSpaceCfg?.id === space.id ? this._curSpaceCfg?.openings || [] : [];
-    const cuts: PartitionOpeningCut[] = [];
-    for (const opening of raw) {
-      if (!opening.host || !accept(opening)) continue;
-      const resolution = resolvePartitionOpeningCompat(
-        opening, space.partitions, NORM_W, this._cellCm, this._gridPitch,
-      );
-      if (resolution.resolved) cuts.push(partitionOpeningCut(resolution.resolved));
-    }
-    return cuts;
+    const config = this._curSpaceCfg?.id === space.id ? this._curSpaceCfg : null;
+    const openings = geometryOpenings(
+      config, space, this._cellCm, this._gridPitch, NORM_W,
+    );
+    return geometryPartitionOpeningCuts(openings, accept);
   }
 
   /**
@@ -8610,22 +8616,11 @@ class HouseplanCard extends LitElement {
   ): Array<{ x: number; y: number; angle: number; length: number }> {
     if (!space) return [];
     const openCuts = this._openPairs().flatMap((pair) => pair.segs);
-    const intervals = wallIntervals(
-      space.rooms, this._spaceWalls, openCuts,
+    return geometryRoomOpeningInputs(
+      openings as readonly GeometryOpeningProjection[],
+      space, this._spaceWalls, openCuts,
       this._wallKeyPitch, this._cellCm, this._gridPitch, NORM_W,
     );
-    return openings.flatMap((opening) => {
-      const input = {
-        x: opening.rx, y: opening.ry,
-        angle: Number(opening.angle) || 0,
-        length: opening.rlen,
-      };
-      if (!opening.host) return [input];
-      if (!opening.partitionHost) return [];
-      return partitionOpeningHasCompositeRoomWall(
-        opening.partitionHost, intervals, this._gridPitch * 0.0002,
-      ) ? [input] : [];
-    });
   }
 
   private _openingFace(
@@ -10861,35 +10856,13 @@ class HouseplanCard extends LitElement {
     const sp = this._curSpaceCfg;
     const space = this._spaceModel();
     if (!space) return [];
-    return resolveOpenCuts(
-      space.rooms,
-      (sp as any)?.open_spans as OpenSpanEntry[] | undefined,
-      NORM_W,
-      this._gridPitch * 0.02,
-    );
+    return geometryOpenCuts(sp, space, this._gridPitch, NORM_W);
   }
 
   /** Open cuts grouped by room pair (for per-room outline trimming). */
   private _openPairs(): { a: RoomCfg; b: RoomCfg; segs: number[][] }[] {
     const cuts = this._openCuts();
-    if (!cuts.length) return [];
-    const rooms = (this._spaceModel()?.rooms || []).filter((r) => r.id);
-    const eps = this._gridPitch * 0.02;
-    const res: { a: RoomCfg; b: RoomCfg; segs: number[][] }[] = [];
-    for (let i = 0; i < rooms.length; i++) {
-      for (let j = i + 1; j < rooms.length; j++) {
-        const pa = roomPoly(rooms[i]), pb = roomPoly(rooms[j]);
-        if (!pa || !pb) continue;
-        const shared = sharedBoundary(pa, pb, eps);
-        if (!shared.length) continue;
-        const segs = cuts.filter((cut) => {
-          const mid = [(cut[0] + cut[2]) / 2, (cut[1] + cut[3]) / 2];
-          return shared.some((sg) => distToSegment(mid, sg) < eps * 4);
-        });
-        if (segs.length) res.push({ a: rooms[i], b: rooms[j], segs });
-      }
-    }
-    return res;
+    return geometryOpenPairs(this._spaceModel()?.rooms || [], cuts, this._gridPitch);
   }
 
   /**
@@ -14900,10 +14873,19 @@ class HouseplanCard extends LitElement {
    * Preview whole-plan maintenance. Nothing is written here: the pure run
    * produces both the report and the exact config/layout pair to commit.
    */
+  private _checkOptimizeGeometry(config: ServerConfig): OptimizeGeometryPreflightResult {
+    return checkOptimizeGeometry(config, {
+      fallbackSpaceName: (index) => this._t('gs.align_preflight_space', {
+        n: String(index),
+      }),
+    });
+  }
+
   private _openAlignDialog = (): void => {
     if (!this._norm || !this._serverCfg) return;
     const spaces = this._serverCfg.spaces || [];
     const r = optimizePlans(this._serverCfg, this._layout || {});
+    const preflight = r.changed ? this._checkOptimizeGeometry(r.config) : null;
     // The maximum geometry shift is an UPPER BOUND, not a sample. The run
     // measured every element in the centimetres of ITS OWN space — converting
     // one normalised maximum through the first space's `cell_cm` understated
@@ -14914,7 +14896,7 @@ class HouseplanCard extends LitElement {
     const where = spaces.length > 1 && sp ? String(sp.title || sp.id) : '';
     this._alignDialog = {
       report: r.report, config: r.config, layout: r.layout, cm, where,
-      changed: r.changed, busy: false,
+      preflight, changed: r.changed, busy: false,
     };
   };
 
@@ -14923,8 +14905,15 @@ class HouseplanCard extends LitElement {
    * one-deep snapshot that remains undoable until the next plan edit.
    */
   private async _runAlignToGrid(): Promise<void> {
-    const d = this._alignDialog;
-    if (!d || d.busy || !this._serverCfg) return;
+    let d = this._alignDialog;
+    if (!d || d.busy || !this._serverCfg || !d.changed || !d.preflight?.ok) return;
+    const fingerprint = contentFingerprint(d.config);
+    if (d.preflight.fingerprint !== fingerprint) {
+      const preflight = this._checkOptimizeGeometry(d.config);
+      d = { ...d, preflight };
+      this._alignDialog = d;
+      if (!preflight.ok) return;
+    }
     this._clearGeometryGesture();
     this._alignDialog = { ...d, busy: true };
     try {
@@ -15937,10 +15926,24 @@ class HouseplanCard extends LitElement {
   private _renderAlignDialog(): TemplateResult {
     const d = this._alignDialog!;
     const r = d.report;
+    const failed = d.changed && !d.preflight?.ok;
+    const failures = d.preflight?.failures || [];
+    const visibleNames = failures.slice(0, 3).map((failure) => failure.displayName);
+    const spaces = visibleNames.length
+      ? visibleNames.join(', ')
+      : this._t('gs.align_preflight_space', { n: '1' });
+    const remaining = Math.max(0, failures.length - visibleNames.length);
+    const more = remaining
+      ? this._t('gs.align_preflight_more', { n: String(remaining) })
+      : '';
     return html`<hp-dialog .hass=${this.hass} .title=${this._t('gs.align_title')} icon="mdi:broom"
       dismiss-on-scrim @hp-close=${() => (this._alignDialog = null)}>
         <div class="body">
-          ${!d.changed
+          ${failed
+            ? html`
+              <p class="alignmsg">${this._t('gs.align_preflight_failed', { spaces, more })}</p>
+              <div class="rhint">${this._t('gs.align_preflight_hint')}</div>`
+            : !d.changed
             ? html`<p class="alignmsg">${this._t('gs.align_none')}</p>`
             : html`
               ${r.moved ? html`<p class="alignmsg">${this._t('gs.align_count', {
@@ -15973,7 +15976,7 @@ class HouseplanCard extends LitElement {
         <div class="row" slot="footer">
           <span class="spacer"></span>
           <button class="btn ghost" @click=${() => (this._alignDialog = null)}>${this._t('btn.cancel')}</button>
-          ${!d.changed ? nothing : html`
+          ${!d.changed || !d.preflight?.ok ? nothing : html`
             <button class="btn on" @click=${this._runAlignToGrid} ?disabled=${d.busy}>
               <ha-icon icon="mdi:check"></ha-icon>${d.busy ? '…' : this._t('gs.align_run')}
             </button>`}

src/i18n/en.json

@@ -794,6 +794,10 @@
   "gs.align_where": "The largest shift is in “{s}”.",
   "gs.align_turned": "Openings whose angle is corrected: {n}.",
   "gs.align_removed_drafts": "Invalid outlines collapsed by the grid and removed: {n}.",
+  "gs.align_preflight_failed": "Could not safely verify the geometry of the following spaces: {spaces}{more}.",
+  "gs.align_preflight_hint": "Plans were not changed. Update House Plan and try again. If the error persists, attach a space export to the bug report.",
+  "gs.align_preflight_space": "Space {n}",
+  "gs.align_preflight_more": ", and {n} more",
   "gs.optimize_changes": "Model migrations: {m}; spaces updated: {c}; noisy coordinate values removed: {p}; merged real-wall fragments: {w}; virtual fragments: {s}; independent walls: {i}.",
   "gs.optimize_glow_migration": "Legacy Glow: {spaces} spaces → no data fill + independent Glow; {rooms} rooms → inherited data fill + independent Glow.",
   "gs.align_warn": "Elements deliberately placed between grid nodes will move. One undo is available after the operation, only until the next plan edit.",

src/i18n/ru.json

@@ -794,6 +794,10 @@
   "gs.align_where": "Наибольший сдвиг — в пространстве «{s}».",
   "gs.align_turned": "Проёмов с исправлением угла: {n}.",
   "gs.align_removed_drafts": "Схлопнувшиеся на сетке некорректные контуры удалены: {n}.",
+  "gs.align_preflight_failed": "Не удалось безопасно проверить геометрию следующих пространств: {spaces}{more}.",
+  "gs.align_preflight_hint": "Планы не изменены. Обновите House Plan и повторите. Если ошибка останется, приложите экспорт пространства к отчёту об ошибке.",
+  "gs.align_preflight_space": "Пространство {n}",
+  "gs.align_preflight_more": " и ещё {n}",
   "gs.optimize_changes": "Миграций модели: {m}; обновлено пространств: {c}; устранён шум координат: {p}; объединено отрезков реальных стен: {w}; виртуальных: {s}; независимых: {i}.",
   "gs.optimize_glow_migration": "Старый Glow: пространств — {spaces} → без заливки данных + независимый Glow; комнат — {rooms} → наследуемая заливка + независимый Glow.",
   "gs.align_warn": "Элементы, намеренно поставленные между узлами, будут сдвинуты. После операции доступна одна отмена — только до следующего изменения плана.",

src/plan-geometry-preflight.ts

@@ -0,0 +1,337 @@
+/**
+ * Pure production-geometry preparation and the explicit Optimize preflight.
+ *
+ * This module deliberately owns no Lit, DOM or Home Assistant state. The card
+ * uses the same preparation helpers for its renderer, so the safety check
+ * cannot quietly drift into a second, simplified geometry algorithm.
+ */
+import { distToSegment, roomPoly, sharedBoundary } from './logic';
+import { resolveOpenCuts, type OpenSpanEntry } from './open-spans';
+import {
+  partitionOpeningCut,
+  partitionOpeningHasCompositeRoomWall,
+  resolvePartitionOpeningCompat,
+  type ResolvedPartitionOpening,
+} from './partition-openings';
+import { physicalBodyParts, type PartitionOpeningCut } from './physical-geometry';
+import {
+  floorFootprintGeometry,
+  wallBodiesGeometry,
+  wallIntervals,
+  type WallEntry,
+} from './wall-thickness';
+import {
+  GRID_PITCH,
+  GRID_STEP_N,
+  NORM_W,
+  spaceModels,
+} from './space-geometry';
+import type { OpeningCfg, ServerConfig, SpaceModel } from './types';
+import { contentFingerprint } from './visual-continuity';
+
+export interface GeometryOpeningProjection extends OpeningCfg {
+  rx: number;
+  ry: number;
+  rlen: number;
+  partitionHost?: ResolvedPartitionOpening;
+}
+
+export interface RoomOpeningGeometryInput {
+  x: number;
+  y: number;
+  angle: number;
+  length: number;
+}
+
+export interface SpacePhysicalGeometryInputs {
+  space: SpaceModel;
+  walls: WallEntry[];
+  openCuts: number[][];
+  openings: GeometryOpeningProjection[];
+  roomOpenings: RoomOpeningGeometryInput[];
+  partitionCuts: PartitionOpeningCut[];
+  physicalBodies: number[][][];
+  wallKeyPitch: number;
+  cellCm: number;
+  gridPitch: number;
+  coordScale: number;
+}
+
+export type OptimizeGeometryFailureReason =
+  | 'prepare-exception'
+  | 'wall-null'
+  | 'wall-exception'
+  | 'floor-null'
+  | 'floor-exception';
+
+export type OptimizeSpaceGeometryStatus = 'ok' | 'failed' | 'not-applicable';
+
+export interface OptimizeSpaceGeometryCheck {
+  spaceId: string;
+  displayName: string;
+  status: OptimizeSpaceGeometryStatus;
+  reason?: OptimizeGeometryFailureReason;
+}
+
+export interface OptimizeGeometryPreflightResult {
+  fingerprint: string;
+  spaces: OptimizeSpaceGeometryCheck[];
+  failures: Array<OptimizeSpaceGeometryCheck & {
+    status: 'failed'; reason: OptimizeGeometryFailureReason;
+  }>;
+  ok: boolean;
+}
+
+export interface CheckOptimizeGeometryOptions {
+  fallbackSpaceName?: (oneBasedIndex: number) => string;
+  prepareSpace?: typeof prepareSpacePhysicalGeometryInputs;
+  wallPass?: typeof wallBodiesGeometry;
+  floorPass?: typeof floorFootprintGeometry;
+  fingerprint?: typeof contentFingerprint;
+}
+
+/** Resolve explicit spans and the legacy open_to fallback exactly as the card. */
+export function geometryOpenCuts(
+  spaceConfig: any,
+  space: Pick<SpaceModel, 'rooms'>,
+  gridPitch = GRID_PITCH,
+  coordScale = NORM_W,
+): number[][] {
+  return resolveOpenCuts(
+    space.rooms,
+    spaceConfig?.open_spans as OpenSpanEntry[] | undefined,
+    coordScale,
+    gridPitch * 0.02,
+  );
+}
+
+/**
+ * Group open cuts by the two rooms that own their shared boundary. Wall
+ * masonry has historically consumed this filtered/ordered projection rather
+ * than the raw span array; both renderer and preflight share it here.
+ */
+export function geometryOpenPairs(
+  roomsInput: readonly any[],
+  cuts: readonly number[][],
+  gridPitch = GRID_PITCH,
+): Array<{ a: any; b: any; segs: number[][] }> {
+  if (!cuts.length) return [];
+  const rooms = roomsInput.filter((room) => room?.id);
+  const eps = gridPitch * 0.02;
+  const result: Array<{ a: any; b: any; segs: number[][] }> = [];
+  for (let left = 0; left < rooms.length; left++) {
+    for (let right = left + 1; right < rooms.length; right++) {
+      const a = rooms[left], b = rooms[right];
+      const polygonA = roomPoly(a), polygonB = roomPoly(b);
+      if (!polygonA || !polygonB) continue;
+      const shared = sharedBoundary(polygonA, polygonB, eps);
+      if (!shared.length) continue;
+      const segs = cuts.filter((cut) => {
+        const midpoint = [(cut[0] + cut[2]) / 2, (cut[1] + cut[3]) / 2];
+        return shared.some((segment) => distToSegment(midpoint, segment) < eps * 4);
+      }).map((cut) => [...cut]);
+      if (segs.length) result.push({ a, b, segs });
+    }
+  }
+  return result;
+}
+
+/** Project stored openings into render units; invalid hosted records stay inert. */
+export function geometryOpenings(
+  spaceConfig: any,
+  space: Pick<SpaceModel, 'partitions'>,
+  cellCm: number,
+  gridPitch = GRID_PITCH,
+  coordScale = NORM_W,
+): GeometryOpeningProjection[] {
+  const raw = Array.isArray(spaceConfig?.openings) ? spaceConfig.openings : [];
+  return raw.flatMap((opening: OpeningCfg) => {
+    const fallback: GeometryOpeningProjection = {
+      ...opening,
+      rx: Number(opening.x) * coordScale,
+      ry: Number(opening.y) * coordScale,
+      rlen: Number(opening.length) * coordScale,
+    };
+    if (!opening.host) return [fallback];
+    const resolution = resolvePartitionOpeningCompat(
+      opening, space.partitions, coordScale, cellCm, gridPitch,
+    );
+    if (!resolution.resolved) return [];
+    return [{
+      ...opening,
+      rx: resolution.resolved.center[0],
+      ry: resolution.resolved.center[1],
+      rlen: resolution.resolved.length,
+      angle: resolution.resolved.angle,
+      partitionHost: resolution.resolved,
+    }];
+  });
+}
+
+export function geometryPartitionOpeningCuts(
+  openings: readonly GeometryOpeningProjection[],
+  accept: (opening: OpeningCfg) => boolean = () => true,
+): PartitionOpeningCut[] {
+  return openings.flatMap((opening) => (
+    opening.host && opening.partitionHost && accept(opening)
+      ? [partitionOpeningCut(opening.partitionHost)]
+      : []
+  ));
+}
+
+/**
+ * Room masonry is cut by a hosted opening only for the exact composite wall
+ * rule used by the production card. Ordinary openings always remain inputs.
+ */
+export function geometryRoomOpeningInputs(
+  openings: readonly GeometryOpeningProjection[],
+  space: Pick<SpaceModel, 'rooms'>,
+  walls: readonly WallEntry[],
+  openCuts: number[][],
+  wallKeyPitch: number,
+  cellCm: number,
+  gridPitch = GRID_PITCH,
+  coordScale = NORM_W,
+): RoomOpeningGeometryInput[] {
+  const intervals = wallIntervals(
+    space.rooms, [...walls], openCuts,
+    wallKeyPitch, cellCm, gridPitch, coordScale,
+  );
+  return openings.flatMap((opening) => {
+    const input = {
+      x: opening.rx,
+      y: opening.ry,
+      angle: Number(opening.angle) || 0,
+      length: opening.rlen,
+    };
+    if (!opening.host) return [input];
+    if (!opening.partitionHost) return [];
+    return partitionOpeningHasCompositeRoomWall(
+      opening.partitionHost, intervals, gridPitch * 0.0002,
+    ) ? [input] : [];
+  });
+}
+
+/** Prepare every argument consumed by the production boolean passes. */
+export function prepareSpacePhysicalGeometryInputs(
+  spaceConfig: any,
+  space: SpaceModel,
+): SpacePhysicalGeometryInputs {
+  const wallKeyPitch = GRID_STEP_N;
+  const gridPitch = GRID_PITCH;
+  const coordScale = NORM_W;
+  const cellCm = Number.isFinite(Number(space.cellCm)) && Number(space.cellCm) > 0
+    ? Number(space.cellCm) : 5;
+  const walls = Array.isArray(spaceConfig?.walls)
+    ? spaceConfig.walls as WallEntry[] : [];
+  const cuts = geometryOpenCuts(spaceConfig, space, gridPitch, coordScale);
+  const openCuts = geometryOpenPairs(space.rooms, cuts, gridPitch)
+    .flatMap((pair) => pair.segs);
+  const openings = geometryOpenings(
+    spaceConfig, space, cellCm, gridPitch, coordScale,
+  );
+  const partitionCuts = geometryPartitionOpeningCuts(openings);
+  const physicalBodies = physicalBodyParts(
+    space, cellCm, gridPitch, gridPitch * 0.0002, partitionCuts,
+  ).all;
+  const roomOpenings = geometryRoomOpeningInputs(
+    openings, space, walls, openCuts,
+    wallKeyPitch, cellCm, gridPitch, coordScale,
+  );
+  return {
+    space, walls, openCuts, openings, roomOpenings, partitionCuts,
+    physicalBodies, wallKeyPitch, cellCm, gridPitch, coordScale,
+  };
+}
+
+function safeDisplayName(
+  spaceConfig: any,
+  index: number,
+  fallback: (oneBasedIndex: number) => string,
+): { spaceId: string; displayName: string } {
+  const title = typeof spaceConfig?.title === 'string' ? spaceConfig.title.trim() : '';
+  const id = spaceConfig?.id == null ? '' : String(spaceConfig.id).trim();
+  return {
+    spaceId: id,
+    displayName: title || id || fallback(index + 1),
+  };
+}
+
+/**
+ * Fail-closed renderability check for the exact config returned by Optimize.
+ * Geometry values never escape this call; the dialog retains only bounded
+ * statuses, names and the candidate fingerprint.
+ */
+export function checkOptimizeGeometry(
+  config: ServerConfig | any,
+  options: CheckOptimizeGeometryOptions = {},
+): OptimizeGeometryPreflightResult {
+  const fingerprint = (options.fingerprint || contentFingerprint)(config);
+  const rawSpaces = Array.isArray(config?.spaces) ? config.spaces : [];
+  const fallback = options.fallbackSpaceName || ((index: number) => `Space ${index}`);
+  const prepare = options.prepareSpace || prepareSpacePhysicalGeometryInputs;
+  const buildWalls = options.wallPass || wallBodiesGeometry;
+  const buildFloor = options.floorPass || floorFootprintGeometry;
+  const spaces: OptimizeSpaceGeometryCheck[] = [];
+
+  for (let index = 0; index < rawSpaces.length; index++) {
+    const raw = rawSpaces[index];
+    const identity = safeDisplayName(raw, index, fallback);
+    let input: SpacePhysicalGeometryInputs;
+    try {
+      const model = spaceModels({ ...config, spaces: [raw] } as ServerConfig)[0];
+      if (!model) throw new Error('missing space model');
+      input = prepare(raw, model);
+    } catch {
+      spaces.push({ ...identity, status: 'failed', reason: 'prepare-exception' });
+      continue;
+    }
+
+    const hasWallPass = input.walls.length > 0 || input.physicalBodies.length > 0;
+    if (!input.space.rooms.length && !hasWallPass) {
+      spaces.push({ ...identity, status: 'not-applicable' });
+      continue;
+    }
+
+    let united: ReturnType<typeof wallBodiesGeometry> = null;
+    if (hasWallPass) {
+      try {
+        united = buildWalls(
+          input.space.rooms, input.walls, input.openCuts, input.roomOpenings,
+          input.wallKeyPitch, input.cellCm, input.gridPitch, input.coordScale,
+          input.physicalBodies,
+        );
+      } catch {
+        spaces.push({ ...identity, status: 'failed', reason: 'wall-exception' });
+        continue;
+      }
+      if (united == null) {
+        spaces.push({ ...identity, status: 'failed', reason: 'wall-null' });
+        continue;
+      }
+    }
+
+    if (input.space.rooms.length && united?.paperGeom == null) {
+      let floor: ReturnType<typeof floorFootprintGeometry>;
+      try {
+        floor = buildFloor(
+          input.space.rooms, input.walls, input.openCuts,
+          input.wallKeyPitch, input.cellCm, input.gridPitch, input.coordScale,
+        );
+      } catch {
+        spaces.push({ ...identity, status: 'failed', reason: 'floor-exception' });
+        continue;
+      }
+      if (floor == null) {
+        spaces.push({ ...identity, status: 'failed', reason: 'floor-null' });
+        continue;
+      }
+    }
+    spaces.push({ ...identity, status: 'ok' });
+  }
+
+  const failures = spaces.filter((space): space is typeof space & {
+    status: 'failed'; reason: OptimizeGeometryFailureReason;
+  } => space.status === 'failed');
+  return { fingerprint, spaces, failures, ok: failures.length === 0 };
+}

test/golden-matrix.test.mjs

@@ -234,7 +234,7 @@ test('sun-ray golden requires browser-painted light from a state-only sun entity
   assert.ok(scenario);
   const fixture = prepareGoldenFixture(scenario);
   const space = fixture.config.spaces.find((item) => item.id === scenario.space);
-  assert.equal(GOLDEN_MATRIX_VERSION, 33);
+  assert.equal(GOLDEN_MATRIX_VERSION, 34);
   assert.equal(space.settings.sun_rays, true);
   assert.equal(scenario.northDeg, 90,
     'the sign-sensitive golden must keep a non-zero north direction');
@@ -507,6 +507,18 @@ test('device dialog goldens expose the complete light-source controls at desktop
     'the harness must activate the declared light-controls scenario flag');
 });
 
+test('issue #199 golden candidates cover the blocked Optimize dialog in both themes', () => {
+  const scenarios = GOLDEN_SCENARIOS.filter((scenario) =>
+    scenario.id.startsWith('optimize-preflight-dialog-'));
+  assert.equal(scenarios.length, 2);
+  assert.deepEqual(new Set(scenarios.map((scenario) => scenario.theme)), new Set(['dark', 'light']));
+  assert.deepEqual(new Set(scenarios.map((scenario) => scenario.language)), new Set(['en', 'ru']));
+  for (const scenario of scenarios) {
+    assert.equal(scenario.dialog, 'optimize-preflight');
+    assert.equal(scenario.capture, 'page');
+  }
+});
+
 test('golden harness neutralizes the shared pointer before every scenario', () => {
   const harness = readFileSync(new URL('../demo/golden/harness.mjs', import.meta.url), 'utf8');
   const reset = harness.indexOf('await page.mouse.move(0, 0);');

test/plan-geometry-preflight.test.mjs

@@ -0,0 +1,163 @@
+import test from 'node:test';
+import assert from 'node:assert/strict';
+
+import {
+  checkOptimizeGeometry,
+  prepareSpacePhysicalGeometryInputs,
+} from '../test-build/plan-geometry-preflight.js';
+import { GRID_STEP_N, spaceModels } from '../test-build/space-geometry.js';
+import { contentFingerprint } from '../test-build/visual-continuity.js';
+import { wallKey } from '../test-build/wall-thickness.js';
+
+const clone = (value) => structuredClone(value);
+const room = (id = 'room') => ({
+  id,
+  poly: [[0.1, 0.1], [0.9, 0.1], [0.9, 0.9], [0.1, 0.9]],
+});
+const wall = (cm = 20) => ({
+  key: wallKey([0.1, 0.1], [0.9, 0.1], GRID_STEP_N),
+  a: [0.1, 0.1], b: [0.9, 0.1], cm,
+});
+const base = (spaces) => ({ model_version: 6, spaces, markers: [], settings: {} });
+
+test('Optimize geometry preflight covers the production input matrix without mutating config', () => {
+  const config = base([
+    {
+      id: 'room-wall', title: 'Room wall', view_box: [0, 0, 1, 1], cell_cm: 5,
+      rooms: [room()], walls: [wall()],
+      openings: [{
+        id: 'ordinary', type: 'door', x: 0.5, y: 0.1,
+        angle: 0, length: 0.1,
+      }],
+    },
+    {
+      id: 'hosted', title: 'Hosted', view_box: [0, 0, 1, 1], cell_cm: 5,
+      rooms: [room('host-room')], walls: [wall(18)],
+      partitions: [{ id: 'partition', a: [0.1, 0.1], b: [0.9, 0.1], cm: 15 }],
+      openings: [{
+        id: 'hosted-opening', type: 'passage', x: 0, y: 0,
+        angle: 0, length: 0.1,
+        host: { kind: 'partition', id: 'partition', t: 0.5 },
+      }],
+    },
+    {
+      id: 'physical-only', title: 'Physical only', view_box: [0, 0, 1, 1], cell_cm: 5,
+      rooms: [],
+      partitions: [{ id: 'p', a: [0.1, 0.2], b: [0.8, 0.2], cm: 15 }],
+      room_drafts: [{
+        id: 'draft', points: [[0.1, 0.4], [0.8, 0.4]], segments: [{ cm: 12 }],
+      }],
+      wall_columns: [{ id: 'column', shape: 'square', center: [0.5, 0.6], cm: 20 }],
+    },
+    {
+      id: 'image-only', title: 'Image only', view_box: [0, 0, 1, 1],
+      plan_url: '/local/plan.png', rooms: [],
+    },
+    { id: 'empty', title: 'Empty', view_box: [0, 0, 1, 1], rooms: [] },
+    { id: 'floor-only', title: 'Floor only', view_box: [0, 0, 1, 1], rooms: [room('floor')] },
+  ]);
+  const before = clone(config);
+
+  const result = checkOptimizeGeometry(config);
+
+  assert.deepEqual(config, before);
+  assert.equal(result.fingerprint, contentFingerprint(config));
+  assert.equal(result.ok, true);
+  assert.deepEqual(result.spaces.map(({ spaceId, status }) => ({ spaceId, status })), [
+    { spaceId: 'room-wall', status: 'ok' },
+    { spaceId: 'hosted', status: 'ok' },
+    { spaceId: 'physical-only', status: 'ok' },
+    { spaceId: 'image-only', status: 'not-applicable' },
+    { spaceId: 'empty', status: 'not-applicable' },
+    { spaceId: 'floor-only', status: 'ok' },
+  ]);
+});
+
+test('production preparation resolves ordinary and hosted openings once for masonry and bodies', () => {
+  const raw = {
+    id: 'parity', title: 'Parity', view_box: [0, 0, 1, 1], cell_cm: 5,
+    rooms: [room()], walls: [wall()],
+    partitions: [{ id: 'partition', a: [0.1, 0.1], b: [0.9, 0.1], cm: 15 }],
+    openings: [
+      { id: 'ordinary', type: 'door', x: 0.3, y: 0.1, angle: 0, length: 0.08 },
+      {
+        id: 'hosted', type: 'passage', x: 0, y: 0, angle: 0, length: 0.08,
+        host: { kind: 'partition', id: 'partition', t: 0.7 },
+      },
+      {
+        id: 'orphan', type: 'door', x: 0.4, y: 0.4, angle: 0, length: 0.08,
+        host: { kind: 'partition', id: 'missing', t: 0.5 },
+      },
+    ],
+  };
+  const model = spaceModels(base([raw]))[0];
+  const input = prepareSpacePhysicalGeometryInputs(raw, model);
+
+  assert.deepEqual(input.openings.map((opening) => opening.id), ['ordinary', 'hosted']);
+  assert.equal(input.partitionCuts.length, 1);
+  assert.equal(input.roomOpenings.length, 2, 'coincident hosted wall cuts room masonry too');
+  assert.ok(input.physicalBodies.length >= 2, 'partition and its opening jamb bodies are retained');
+  assert.equal(input.wallKeyPitch, GRID_STEP_N);
+  assert.equal(input.cellCm, 5);
+});
+
+test('null, exceptions and floor failure are bounded while successful empty geometry stays green', () => {
+  const wallConfig = base([{
+    id: 'wall-space', title: 'Wall space', view_box: [0, 0, 1, 1],
+    rooms: [room()], walls: [wall()],
+  }]);
+  const floorConfig = base([{
+    id: 'floor-space', title: 'Floor space', view_box: [0, 0, 1, 1], rooms: [room()],
+  }]);
+
+  const wallNull = checkOptimizeGeometry(wallConfig, { wallPass: () => null });
+  assert.equal(wallNull.ok, false);
+  assert.equal(wallNull.failures[0].reason, 'wall-null');
+
+  const wallThrows = checkOptimizeGeometry(wallConfig, { wallPass: () => { throw new Error('secret'); } });
+  assert.equal(wallThrows.failures[0].reason, 'wall-exception');
+  assert.doesNotMatch(JSON.stringify(wallThrows), /secret/);
+
+  const successfulEmpty = checkOptimizeGeometry(wallConfig, {
+    wallPass: () => ({ geom: [], paperGeom: [], depthUnits: 0, openingIndex: null }),
+    floorPass: () => { throw new Error('must not run'); },
+  });
+  assert.equal(successfulEmpty.ok, true);
+
+  const floorNull = checkOptimizeGeometry(floorConfig, { floorPass: () => null });
+  assert.equal(floorNull.failures[0].reason, 'floor-null');
+  const floorThrows = checkOptimizeGeometry(floorConfig, {
+    floorPass: () => { throw new Error('private floor detail'); },
+  });
+  assert.equal(floorThrows.failures[0].reason, 'floor-exception');
+  assert.doesNotMatch(JSON.stringify(floorThrows), /private floor detail/);
+
+  const prepareThrows = checkOptimizeGeometry(wallConfig, {
+    prepareSpace: () => { throw new Error('private preparation detail'); },
+  });
+  assert.equal(prepareThrows.failures[0].reason, 'prepare-exception');
+  assert.doesNotMatch(JSON.stringify(prepareThrows), /private preparation detail/);
+});
+
+test('one failed space blocks the ordered whole-plan result and uses safe display fallbacks', () => {
+  const config = base([
+    { id: 'good', title: ' Good floor ', view_box: [0, 0, 1, 1], rooms: [] },
+    { id: 'bad-id', title: ' ', view_box: [0, 0, 1, 1], rooms: [room()] },
+    { id: '', title: '', view_box: [0, 0, 1, 1], rooms: [room()] },
+  ]);
+  const result = checkOptimizeGeometry(config, {
+    fallbackSpaceName: (index) => `Fallback ${index}`,
+    floorPass: (rooms) => rooms[0]?.id === 'room' ? null : [],
+  });
+
+  assert.equal(result.ok, false);
+  assert.deepEqual(result.spaces.map((space) => space.displayName), [
+    'Good floor', 'bad-id', 'Fallback 3',
+  ]);
+  assert.deepEqual(result.failures.map(({ spaceId, displayName, reason }) => ({
+    spaceId, displayName, reason,
+  })), [
+    { spaceId: 'bad-id', displayName: 'bad-id', reason: 'floor-null' },
+    { spaceId: '', displayName: 'Fallback 3', reason: 'floor-null' },
+  ]);
+});

tsconfig.test.json

@@ -29,6 +29,7 @@
     "src/serialized-write-queue.ts",
     "src/align-grid.ts",
     "src/plan-optimizer.ts",
+    "src/plan-geometry-preflight.ts",
     "src/furniture.ts",
     "src/floating-surface.ts", "src/floating-surface-controller.ts", "src/help-behavior.ts",
     "src/hp-help.ts", "src/hp-dialog.ts", "src/hp-color-opacity.ts",