trim down

examples/01_simple_route.py

@@ -23,7 +23,7 @@ def main() -> None:
 
     # 2. Configure Router
     evaluator = CostEvaluator(engine, danger_map)
-    context = AStarContext(evaluator, snap_size=1.0, bend_radii=[10.0])
+    context = AStarContext(evaluator, bend_radii=[10.0])
     metrics = AStarMetrics()
     pf = PathFinder(context, metrics)
 

examples/02_congestion_resolution.py

@@ -18,7 +18,7 @@ def main() -> None:
 
     # Configure a router with high congestion penalties
     evaluator = CostEvaluator(engine, danger_map, greedy_h_weight=1.5, bend_penalty=50.0, sbend_penalty=150.0)
-    context = AStarContext(evaluator, snap_size=1.0, bend_radii=[10.0], sbend_radii=[10.0])
+    context = AStarContext(evaluator, bend_radii=[10.0], sbend_radii=[10.0])
     metrics = AStarMetrics()
     pf = PathFinder(context, metrics, base_congestion_penalty=1000.0)
 

examples/03_locked_paths.py

@@ -17,7 +17,7 @@ def main() -> None:
     danger_map.precompute([])
 
     evaluator = CostEvaluator(engine, danger_map)
-    context = AStarContext(evaluator, snap_size=1.0, bend_radii=[10.0])
+    context = AStarContext(evaluator, bend_radii=[10.0])
     metrics = AStarMetrics()
     pf = PathFinder(context, metrics)
 

examples/04_sbends_and_radii.py

@@ -28,7 +28,6 @@ def main() -> None:
     context = AStarContext(
         evaluator,
         node_limit=50000,
-        snap_size=1.0,
         bend_radii=[10.0, 30.0],
         sbend_offsets=[5.0], # Use a simpler offset
         bend_penalty=10.0,

examples/05_orientation_stress.py

@@ -17,7 +17,7 @@ def main() -> None:
     danger_map.precompute([])
 
     evaluator = CostEvaluator(engine, danger_map, bend_penalty=50.0)
-    context = AStarContext(evaluator, snap_size=5.0, bend_radii=[20.0])
+    context = AStarContext(evaluator, bend_radii=[20.0])
     metrics = AStarMetrics()
     pf = PathFinder(context, metrics)
 

examples/06_bend_collision_models.py

@@ -33,15 +33,15 @@ def main() -> None:
     evaluator = CostEvaluator(engine, danger_map, bend_penalty=50.0, sbend_penalty=150.0)
 
     # Scenario 1: Standard 'arc' model (High fidelity)
-    context_arc = AStarContext(evaluator, snap_size=1.0, bend_radii=[10.0], bend_collision_type="arc")
+    context_arc = AStarContext(evaluator, bend_radii=[10.0], bend_collision_type="arc")
     netlist_arc = {"arc_model": (Port(10, 120, 0), Port(90, 140, 90))}
 
     # Scenario 2: 'bbox' model (Conservative axis-aligned box)
-    context_bbox = AStarContext(evaluator, snap_size=1.0, bend_radii=[10.0], bend_collision_type="bbox")
+    context_bbox = AStarContext(evaluator, bend_radii=[10.0], bend_collision_type="bbox")
     netlist_bbox = {"bbox_model": (Port(10, 70, 0), Port(90, 90, 90))}
 
     # Scenario 3: 'clipped_bbox' model (Balanced)
-    context_clipped = AStarContext(evaluator, snap_size=1.0, bend_radii=[10.0], bend_collision_type="clipped_bbox", bend_clip_margin=1.0)
+    context_clipped = AStarContext(evaluator, bend_radii=[10.0], bend_collision_type="clipped_bbox", bend_clip_margin=1.0)
     netlist_clipped = {"clipped_model": (Port(10, 20, 0), Port(90, 40, 90))}
 
     # 2. Route each scenario

examples/07_large_scale_routing.py

@@ -10,7 +10,7 @@ from inire.utils.visualization import plot_routing_results, plot_danger_map, plo
 from shapely.geometry import box
 
 def main() -> None:
-    print("Running Example 07: Fan-Out (10 Nets, 50um Radius, 5um Grid)...")
+    print("Running Example 07: Fan-Out (10 Nets, 50um Radius)...")
 
     # 1. Setup Environment
     bounds = (0, 0, 1000, 1000)
@@ -29,7 +29,7 @@ def main() -> None:
 
     evaluator = CostEvaluator(engine, danger_map, greedy_h_weight=1.5, unit_length_cost=0.1, bend_penalty=100.0, sbend_penalty=400.0, congestion_penalty=100.0)
 
-    context = AStarContext(evaluator, node_limit=2000000, snap_size=5.0, bend_radii=[50.0], sbend_radii=[50.0])
+    context = AStarContext(evaluator, node_limit=2000000, bend_radii=[50.0], sbend_radii=[50.0])
     metrics = AStarMetrics()
     pf = PathFinder(context, metrics, max_iterations=15, base_congestion_penalty=100.0, congestion_multiplier=1.4)
 
@@ -44,8 +44,8 @@ def main() -> None:
     end_y_pitch = 800.0 / (num_nets - 1)
 
     for i in range(num_nets):
-        sy = round((start_y_base + i * 10.0) / 5.0) * 5.0
-        ey = round((end_y_base + i * end_y_pitch) / 5.0) * 5.0
+        sy = int(round(start_y_base + i * 10.0))
+        ey = int(round(end_y_base + i * end_y_pitch))
         netlist[f"net_{i:02d}"] = (Port(start_x, sy, 0), Port(end_x, ey, 0))
 
     net_widths = {nid: 2.0 for nid in netlist}
@@ -60,38 +60,7 @@ def main() -> None:
         total_collisions = sum(r.collisions for r in current_results.values())
         total_nodes = metrics.nodes_expanded
 
-        # Identify Hotspots
-        hotspots = {}
-        overlap_matrix = {} # (net_a, net_b) -> count
-
-        for nid, res in current_results.items():
-            if not res.path:
-                continue
-            for comp in res.path:
-                for poly in comp.geometry:
-                    # Check what it overlaps with
-                    overlaps = engine.dynamic_index.intersection(poly.bounds)
-                    for other_obj_id in overlaps:
-                        if other_obj_id in engine.dynamic_geometries:
-                            other_nid, other_poly = engine.dynamic_geometries[other_obj_id]
-                            if other_nid != nid:
-                                if poly.intersects(other_poly):
-                                    # Record hotspot
-                                    cx, cy = poly.centroid.x, poly.centroid.y
-                                    grid_key = (int(cx/20)*20, int(cy/20)*20)
-                                    hotspots[grid_key] = hotspots.get(grid_key, 0) + 1
-
-                                    # Record pair
-                                    pair = tuple(sorted((nid, other_nid)))
-                                    overlap_matrix[pair] = overlap_matrix.get(pair, 0) + 1
-
         print(f"  Iteration {idx} finished. Successes: {successes}/{len(netlist)}, Collisions: {total_collisions}")
-        if overlap_matrix:
-            top_pairs = sorted(overlap_matrix.items(), key=lambda x: x[1], reverse=True)[:3]
-            print(f"  Top Conflicts: {top_pairs}")
-        if hotspots:
-            top_hotspots = sorted(hotspots.items(), key=lambda x: x[1], reverse=True)[:3]
-            print(f"  Top Hotspots: {top_hotspots}")
         
         # Adaptive Greediness: Decay from 1.5 to 1.1 over 10 iterations
         new_greedy = max(1.1, 1.5 - ((idx + 1) / 10.0) * 0.4)
@@ -104,46 +73,12 @@ def main() -> None:
             'Congestion': total_collisions,
             'Nodes': total_nodes
         })
-
-        # Save plots only for certain iterations to save time
-#        if idx % 20 == 0 or idx == pf.max_iterations - 1:
-        if True:
-            # Save a plot of this iteration's result
-            fig, ax = plot_routing_results(current_results, obstacles, bounds, netlist=netlist)
-            plot_danger_map(danger_map, ax=ax)
-
-            # Overlay failures: show where they stopped
-            for nid, res in current_results.items():
-                if not res.is_valid and res.path:
-                    last_p = res.path[-1].end_port
-                    target_p = netlist[nid][1]
-                    dist = abs(last_p.x - target_p.x) + abs(last_p.y - target_p.y)
-                    ax.scatter(last_p.x, last_p.y, color='red', marker='x', s=100)
-                    ax.text(last_p.x, last_p.y, f" {nid} (rem: {dist:.0f}um)", color='red', fontsize=8)
-
-            fig.savefig(f"examples/07_iteration_{idx:02d}.png")
-            import matplotlib.pyplot as plt
-            plt.close(fig)
-
-            # Plot Expansion Density if data is available
-            if pf.accumulated_expanded_nodes:
-                 fig_d, ax_d = plot_expansion_density(pf.accumulated_expanded_nodes, bounds)
-                 fig_d.savefig(f"examples/07_iteration_{idx:02d}_density.png")
-                 plt.close(fig_d)
-
         metrics.reset_per_route()
 
-    import cProfile, pstats
-    profiler = cProfile.Profile()
-    profiler.enable()
     t0 = time.perf_counter()
     results = pf.route_all(netlist, net_widths, store_expanded=True, iteration_callback=iteration_callback, shuffle_nets=True, seed=42)
     t1 = time.perf_counter()
-    profiler.disable()
 
-    # Final stats
-    stats = pstats.Stats(profiler).sort_stats('tottime')
-    stats.print_stats(20)
     print(f"Routing took {t1-t0:.4f}s")
 
     # 4. Check Results
@@ -157,28 +92,15 @@ def main() -> None:
     print(f"\nFinal: Routed {success_count}/{len(netlist)} nets successfully.")
 
     for nid, res in results.items():
-        target_p = netlist[nid][1]
         if not res.is_valid:
-            last_p = res.path[-1].end_port if res.path else netlist[nid][0]
-            dist = abs(last_p.x - target_p.x) + abs(last_p.y - target_p.y)
-            print(f"  FAILED: {nid} (Stopped {dist:.1f}um from target)")
+            print(f"  FAILED: {nid}, collisions={res.collisions}")
         else:
-            types = [move.move_type for move in res.path]
-            from collections import Counter
-            counts = Counter(types)
-            print(f"  {nid}: {len(res.path)} segments, {dict(counts)}")
+            print(f"  {nid}: SUCCESS")
 
     # 5. Visualize
     fig, ax = plot_routing_results(results, obstacles, bounds, netlist=netlist)
-
-    # Overlay Danger Map
     plot_danger_map(danger_map, ax=ax)
 
-    # Overlay Expanded Nodes from last routed net (as an example)
-    if metrics.last_expanded_nodes:
-        print(f"Plotting {len(metrics.last_expanded_nodes)} expanded nodes for the last net...")
-        plot_expanded_nodes(metrics.last_expanded_nodes, ax=ax, color='blue', alpha=0.1)
-
     fig.savefig("examples/07_large_scale_routing.png")
     print("Saved plot to examples/07_large_scale_routing.png")
 

examples/08_custom_bend_geometry.py

@@ -19,7 +19,7 @@ def main() -> None:
     danger_map.precompute([])
 
     evaluator = CostEvaluator(engine, danger_map, bend_penalty=50.0, sbend_penalty=150.0)
-    context = AStarContext(evaluator, snap_size=1.0, bend_radii=[10.0], sbend_radii=[])
+    context = AStarContext(evaluator, bend_radii=[10.0], sbend_radii=[])
     metrics = AStarMetrics()
     pf = PathFinder(context, metrics)
 
@@ -40,7 +40,7 @@ def main() -> None:
 
     print("Routing with custom collision model...")
     # Override bend_collision_type with a literal Polygon
-    context_custom = AStarContext(evaluator, snap_size=1.0, bend_radii=[10.0], bend_collision_type=custom_poly, sbend_radii=[])
+    context_custom = AStarContext(evaluator, bend_radii=[10.0], bend_collision_type=custom_poly, sbend_radii=[])
     metrics_custom = AStarMetrics()
     results_custom = PathFinder(context_custom, metrics_custom, use_tiered_strategy=False).route_all(
         {"custom_model": netlist["custom_bend"]}, {"custom_model": 2.0}

examples/09_unroutable_best_effort.py

@@ -8,51 +8,49 @@ from inire.utils.visualization import plot_routing_results
 from shapely.geometry import box
 
 def main() -> None:
-    print("Running Example 09: Best-Effort (Unroutable Net)...")
+    print("Running Example 09: Best-Effort Under Tight Search Budget...")
 
     # 1. Setup Environment
     bounds = (0, 0, 100, 100)
     engine = CollisionEngine(clearance=2.0)
 
-    # Create a 'cage' that completely blocks the target
-    cage = [
-        box(70, 30, 75, 70), # Left wall
-        box(70, 70, 95, 75), # Top wall
-        box(70, 25, 95, 30), # Bottom wall
+    # A small obstacle cluster keeps the partial route visually interesting.
+    obstacles = [
+        box(35, 35, 45, 65),
+        box(55, 35, 65, 65),
     ]
-    for obs in cage:
+    for obs in obstacles:
         engine.add_static_obstacle(obs)
 
     danger_map = DangerMap(bounds=bounds)
-    danger_map.precompute(cage)
+    danger_map.precompute(obstacles)
 
     evaluator = CostEvaluator(engine, danger_map, bend_penalty=50.0, sbend_penalty=150.0)
-    # Use a low node limit to fail faster
-    context = AStarContext(evaluator, node_limit=2000, snap_size=1.0, bend_radii=[10.0])
+    # Keep the search budget intentionally tiny so the router returns a partial path.
+    context = AStarContext(evaluator, node_limit=3, bend_radii=[10.0])
     metrics = AStarMetrics()
 
-    # Enable partial path return (handled internally by PathFinder calling route_astar with return_partial=True)
-    pf = PathFinder(context, metrics)
+    pf = PathFinder(context, metrics, warm_start=None)
 
-    # 2. Define Netlist: start outside, target inside the cage
+    # 2. Define Netlist: reaching the target requires additional turns the search budget cannot afford.
     netlist = {
-        "trapped_net": (Port(10, 50, 0), Port(85, 50, 0)),
+        "budget_limited_net": (Port(10, 50, 0), Port(85, 60, 180)),
     }
-    net_widths = {"trapped_net": 2.0}
+    net_widths = {"budget_limited_net": 2.0}
 
     # 3. Route
-    print("Routing net into a cage (should fail and return partial)...")
+    print("Routing with a deliberately tiny node budget (should return a partial path)...")
     results = pf.route_all(netlist, net_widths)
 
     # 4. Check Results
-    res = results["trapped_net"]
-    if not res.is_valid:
-        print(f"Net failed to route as expected. Partial path length: {len(res.path)} segments.")
+    res = results["budget_limited_net"]
+    if not res.reached_target:
+        print(f"Target not reached as expected. Partial path length: {len(res.path)} segments.")
     else:
-        print("Wait, it found a way in? Check the cage geometry!")
+        print("The route unexpectedly reached the target. Increase difficulty or reduce the node budget further.")
 
     # 5. Visualize
-    fig, ax = plot_routing_results(results, cage, bounds, netlist=netlist)
+    fig, ax = plot_routing_results(results, obstacles, bounds, netlist=netlist)
     fig.savefig("examples/09_unroutable_best_effort.png")
     print("Saved plot to examples/09_unroutable_best_effort.png")
 

inire/geometry/collision.py

@@ -23,12 +23,13 @@ class CollisionEngine:
         'clearance', 'max_net_width', 'safety_zone_radius',
         'static_index', 'static_geometries', 'static_dilated', 'static_prepared', 
         'static_is_rect', 'static_tree', 'static_obj_ids', 'static_safe_cache', 
-        'static_grid', 'grid_cell_size', '_static_id_counter',
+        'static_grid', 'grid_cell_size', '_static_id_counter', '_net_specific_trees',
+        '_net_specific_is_rect', '_net_specific_bounds',
         'dynamic_index', 'dynamic_geometries', 'dynamic_dilated', 'dynamic_prepared', 
         'dynamic_tree', 'dynamic_obj_ids', 'dynamic_grid', '_dynamic_id_counter',
         'metrics', '_dynamic_tree_dirty', '_dynamic_net_ids_array', '_inv_grid_cell_size',
         '_static_bounds_array', '_static_is_rect_array', '_locked_nets',
-        '_static_raw_tree', '_static_raw_obj_ids', '_dynamic_bounds_array'
+        '_static_raw_tree', '_static_raw_obj_ids', '_dynamic_bounds_array', '_static_version'
     )
 
     def __init__(
@@ -53,6 +54,10 @@ class CollisionEngine:
         self._static_is_rect_array: numpy.ndarray | None = None
         self._static_raw_tree: STRtree | None = None
         self._static_raw_obj_ids: list[int] = []
+        self._net_specific_trees: dict[tuple[float, float], STRtree] = {}
+        self._net_specific_is_rect: dict[tuple[float, float], numpy.ndarray] = {}
+        self._net_specific_bounds: dict[tuple[float, float], numpy.ndarray] = {}
+        self._static_version = 0
         
         self.static_safe_cache: set[tuple] = set()
         self.static_grid: dict[tuple[int, int], list[int]] = {}
@@ -96,22 +101,21 @@ class CollisionEngine:
                 f"  Congestion: {m['congestion_tree_queries']} checks\n"
                 f"  Safety Zone: {m['safety_zone_checks']} full intersections performed")
 
-    def add_static_obstacle(self, polygon: Polygon) -> int:
+    def add_static_obstacle(self, polygon: Polygon, dilated_geometry: Polygon | None = None) -> int:
         obj_id = self._static_id_counter
         self._static_id_counter += 1
         
-        # Consistent with Wi/2 + C/2 separation:
-        # Buffer static obstacles by half clearance.
-        # Checkers must also buffer waveguide by Wi/2 + C/2.
+        # Preserve existing dilation if provided, else use default C/2
+        if dilated_geometry is not None:
+             dilated = dilated_geometry
+        else:
              dilated = polygon.buffer(self.clearance / 2.0, join_style=2)
         
         self.static_geometries[obj_id] = polygon
         self.static_dilated[obj_id] = dilated
         self.static_prepared[obj_id] = prep(dilated)
         self.static_index.insert(obj_id, dilated.bounds)
-        self.static_tree = None
-        self._static_raw_tree = None
-        self.static_grid = {}
+        self._invalidate_static_caches()
         b = dilated.bounds
         area = (b[2] - b[0]) * (b[3] - b[1])
         self.static_is_rect[obj_id] = (abs(dilated.area - area) < 1e-4)
@@ -131,10 +135,21 @@ class CollisionEngine:
         del self.static_dilated[obj_id]
         del self.static_prepared[obj_id]
         del self.static_is_rect[obj_id]
+        self._invalidate_static_caches()
 
+    def _invalidate_static_caches(self) -> None:
         self.static_tree = None
+        self._static_bounds_array = None
+        self._static_is_rect_array = None
+        self.static_obj_ids = []
         self._static_raw_tree = None
+        self._static_raw_obj_ids = []
         self.static_grid = {}
+        self._net_specific_trees.clear()
+        self._net_specific_is_rect.clear()
+        self._net_specific_bounds.clear()
+        self.static_safe_cache.clear()
+        self._static_version += 1
 
     def _ensure_static_tree(self) -> None:
         if self.static_tree is None and self.static_dilated:
@@ -144,6 +159,37 @@ class CollisionEngine:
             self._static_bounds_array = numpy.array([g.bounds for g in geoms])
             self._static_is_rect_array = numpy.array([self.static_is_rect[i] for i in self.static_obj_ids])
 
+    def _ensure_net_static_tree(self, net_width: float) -> STRtree:
+        """
+        Lazily generate a tree where obstacles are dilated by (net_width/2 + clearance).
+        """
+        key = (round(net_width, 4), round(self.clearance, 4))
+        if key in self._net_specific_trees:
+            return self._net_specific_trees[key]
+        
+        # Physical separation must be >= clearance.
+        # Centerline to raw obstacle edge must be >= net_width/2 + clearance.
+        total_dilation = net_width / 2.0 + self.clearance
+        geoms = []
+        is_rect_list = []
+        bounds_list = []
+        
+        for obj_id in sorted(self.static_geometries.keys()):
+            poly = self.static_geometries[obj_id]
+            dilated = poly.buffer(total_dilation, join_style=2)
+            geoms.append(dilated)
+            
+            b = dilated.bounds
+            bounds_list.append(b)
+            area = (b[2] - b[0]) * (b[3] - b[1])
+            is_rect_list.append(abs(dilated.area - area) < 1e-4)
+        
+        tree = STRtree(geoms)
+        self._net_specific_trees[key] = tree
+        self._net_specific_is_rect[key] = numpy.array(is_rect_list, dtype=bool)
+        self._net_specific_bounds[key] = numpy.array(bounds_list)
+        return tree
+
     def _ensure_static_raw_tree(self) -> None:
         if self._static_raw_tree is None and self.static_geometries:
             self._static_raw_obj_ids = sorted(self.static_geometries.keys())
@@ -205,7 +251,9 @@ class CollisionEngine:
         to_move = [obj_id for obj_id, (nid, _) in self.dynamic_geometries.items() if nid == net_id]
         for obj_id in to_move:
             poly = self.dynamic_geometries[obj_id][1]
-            self.add_static_obstacle(poly)
+            dilated = self.dynamic_dilated[obj_id]
+            # Preserve dilation for perfect consistency
+            self.add_static_obstacle(poly, dilated_geometry=dilated)
             
         # Remove from dynamic index (without triggering the locked-net guard)
         self.dynamic_tree = None
@@ -219,9 +267,9 @@ class CollisionEngine:
     def unlock_net(self, net_id: str) -> None:
         self._locked_nets.discard(net_id)
 
-    def check_move_straight_static(self, start_port: Port, length: float) -> bool:
+    def check_move_straight_static(self, start_port: Port, length: float, net_width: float) -> bool:
         self.metrics['static_straight_fast'] += 1
-        reach = self.ray_cast(start_port, start_port.orientation, max_dist=length + 0.01)
+        reach = self.ray_cast(start_port, start_port.orientation, max_dist=length + 0.01, net_width=net_width)
         return reach < length - 0.001
 
     def _is_in_safety_zone_fast(self, idx: int, start_port: Port | None, end_port: Port | None) -> bool:
@@ -236,19 +284,19 @@ class CollisionEngine:
                  b[1]-sz <= end_port.y <= b[3]+sz): return True
         return False
 
-    def check_move_static(self, result: ComponentResult, start_port: Port | None = None, end_port: Port | None = None) -> bool:
+    def check_move_static(self, result: ComponentResult, start_port: Port | None = None, end_port: Port | None = None, net_width: float | None = None) -> bool:
         if not self.static_dilated: return False
         self.metrics['static_tree_queries'] += 1
         self._ensure_static_tree()
         
-        # 1. Fast total bounds check
-        tb = result.total_bounds
+        # 1. Fast total bounds check (Use dilated bounds to ensure clearance is caught)
+        tb = result.total_dilated_bounds if result.total_dilated_bounds else result.total_bounds
         hits = self.static_tree.query(box(*tb))
         if hits.size == 0: return False
              
         # 2. Per-hit check
         s_bounds = self._static_bounds_array
-        move_poly_bounds = result.bounds
+        move_poly_bounds = result.dilated_bounds if result.dilated_bounds else result.bounds
         for hit_idx in hits:
             obs_b = s_bounds[hit_idx]
             
@@ -266,9 +314,6 @@ class CollisionEngine:
             if self._is_in_safety_zone_fast(hit_idx, start_port, end_port):
                  # If near port, we must use the high-precision check
                  obj_id = self.static_obj_ids[hit_idx]
-                 # Triggers lazy evaluation of geometry only if needed
-                 poly_move = result.geometry[0] # Simplification: assume 1 poly for now or loop
-                 # Actually, better loop over move polygons for high-fidelity
                  collision_found = False
                  for p_move in result.geometry:
                       if not self._is_in_safety_zone(p_move, obj_id, start_port, end_port):
@@ -277,13 +322,14 @@ class CollisionEngine:
                  return True
             
             # Not in safety zone and AABBs overlap - check real intersection
-            # This is the most common path for real collisions or near misses
             obj_id = self.static_obj_ids[hit_idx]
-            raw_obstacle = self.static_geometries[obj_id]
+            # Use dilated geometry (Wi/2 + C/2) against static_dilated (C/2) to get Wi/2 + C.
+            # Touching means gap is exactly C. Intersection without touches means gap < C.
             test_geoms = result.dilated_geometry if result.dilated_geometry else result.geometry
+            static_obs_dilated = self.static_dilated[obj_id]
             
             for i, p_test in enumerate(test_geoms):
-                if p_test.intersects(raw_obstacle):
+                if p_test.intersects(static_obs_dilated) and not p_test.touches(static_obs_dilated):
                     return True
         return False
 
@@ -339,11 +385,11 @@ class CollisionEngine:
         possible_total = (tb[0] < d_bounds[:, 2]) & (tb[2] > d_bounds[:, 0]) & \
                          (tb[1] < d_bounds[:, 3]) & (tb[3] > d_bounds[:, 1])
         
-        valid_hits = (self._dynamic_net_ids_array != net_id)
-        if not numpy.any(possible_total & valid_hits):
+        valid_hits_mask = (self._dynamic_net_ids_array != net_id)
+        if not numpy.any(possible_total & valid_hits_mask):
              return 0
 
-        # 2. Per-polygon AABB check using query on geometries (LAZY triggering)
+        # 2. Per-polygon check using query
         geoms_to_test = result.dilated_geometry if result.dilated_geometry else result.geometry
         res_indices, tree_indices = self.dynamic_tree.query(geoms_to_test, predicate='intersects')
         
@@ -351,8 +397,35 @@ class CollisionEngine:
              return 0
              
         hit_net_ids = numpy.take(self._dynamic_net_ids_array, tree_indices)
-        valid_geoms_hits = (hit_net_ids != net_id)
-        return int(numpy.sum(valid_geoms_hits))
+        
+        # Group by other net_id to minimize 'touches' calls
+        unique_other_nets = numpy.unique(hit_net_ids[hit_net_ids != net_id])
+        if unique_other_nets.size == 0:
+             return 0
+             
+        tree_geoms = self.dynamic_tree.geometries
+        real_hits_count = 0
+        
+        for other_nid in unique_other_nets:
+             other_mask = (hit_net_ids == other_nid)
+             sub_tree_indices = tree_indices[other_mask]
+             sub_res_indices = res_indices[other_mask]
+             
+             # Check if ANY hit for THIS other net is a real collision
+             found_real = False
+             for j in range(len(sub_tree_indices)):
+                  p_test = geoms_to_test[sub_res_indices[j]]
+                  p_tree = tree_geoms[sub_tree_indices[j]]
+                  if not p_test.touches(p_tree):
+                       # Add small area tolerance for numerical precision
+                       if p_test.intersection(p_tree).area > 1e-7:
+                            found_real = True
+                            break
+             
+             if found_real:
+                  real_hits_count += 1
+                  
+        return real_hits_count
 
     def _is_in_safety_zone(self, geometry: Polygon, obj_id: int, start_port: Port | None, end_port: Port | None) -> bool:
         """ 
@@ -392,17 +465,21 @@ class CollisionEngine:
             self._ensure_static_tree()
             if self.static_tree is None: return False
             
-            # Separation needed: (Wi + C)/2.
-            # static_dilated is buffered by C/2.
-            # So we need geometry buffered by Wi/2.
-            if dilated_geometry: 
+            # Separation needed: Centerline-to-WallEdge >= Wi/2 + C.
+            # static_tree has obstacles buffered by C/2.
+            # geometry is physical waveguide (Wi/2 from centerline).
+            # So we buffer geometry by C/2 to get Wi/2 + C/2.
+            # Intersection means separation < (Wi/2 + C/2) + C/2 = Wi/2 + C.
+            if dilated_geometry is not None: 
                  test_geom = dilated_geometry
             else:
-                 dist = (net_width / 2.0) if net_width is not None else 0.0
-                 test_geom = geometry.buffer(dist + 1e-7, join_style=2) if dist >= 0 else geometry
+                 dist = self.clearance / 2.0
+                 test_geom = geometry.buffer(dist + 1e-7, join_style=2) if dist > 0 else geometry
             
             hits = self.static_tree.query(test_geom, predicate='intersects')
+            tree_geoms = self.static_tree.geometries
             for hit_idx in hits:
+                if test_geom.touches(tree_geoms[hit_idx]): continue
                 obj_id = self.static_obj_ids[hit_idx]
                 if self._is_in_safety_zone(geometry, obj_id, start_port, end_port): continue
                 return True
@@ -412,60 +489,166 @@ class CollisionEngine:
         if self.dynamic_tree is None: return 0
         test_poly = dilated_geometry if dilated_geometry else geometry.buffer(self.clearance / 2.0)
         hits = self.dynamic_tree.query(test_poly, predicate='intersects')
-        count = 0
+        tree_geoms = self.dynamic_tree.geometries
+        hit_net_ids = []
         for hit_idx in hits:
+            if test_poly.touches(tree_geoms[hit_idx]): continue
             obj_id = self.dynamic_obj_ids[hit_idx]
-            if self.dynamic_geometries[obj_id][0] != net_id: count += 1
-        return count
+            other_id = self.dynamic_geometries[obj_id][0]
+            if other_id != net_id:
+                 hit_net_ids.append(other_id)
+        return len(numpy.unique(hit_net_ids)) if hit_net_ids else 0
 
     def is_collision(self, geometry: Polygon, net_id: str = 'default', net_width: float | None = None, start_port: Port | None = None, end_port: Port | None = None) -> bool:
         """ Unified entry point for static collision checks. """
         result = self.check_collision(geometry, net_id, buffer_mode='static', start_port=start_port, end_port=end_port, net_width=net_width)
         return bool(result)
 
-    def ray_cast(self, origin: Port, angle_deg: float, max_dist: float = 2000.0) -> float:
+    def verify_path(self, net_id: str, components: list[ComponentResult]) -> tuple[bool, int]:
+        """
+        Non-approximated, full-polygon intersection check of a path against all
+        static obstacles and other nets.
+        """
+        collision_count = 0
+        
+        # 1. Check against static obstacles
+        self._ensure_static_raw_tree()
+        if self._static_raw_tree is not None:
+             raw_geoms = self._static_raw_tree.geometries
+             for comp in components:
+                  # Use ACTUAL geometry, not dilated/proxy
+                  actual_geoms = comp.actual_geometry if comp.actual_geometry is not None else comp.geometry
+                  for p_actual in actual_geoms:
+                       # Physical separation must be >= clearance.
+                       p_verify = p_actual.buffer(self.clearance, join_style=2)
+                       hits = self._static_raw_tree.query(p_verify, predicate='intersects')
+                       for hit_idx in hits:
+                            p_obs = raw_geoms[hit_idx]
+                            # If they ONLY touch, gap is exactly clearance. Valid.
+                            if p_verify.touches(p_obs): continue
+                            
+                            obj_id = self._static_raw_obj_ids[hit_idx]
+                            if not self._is_in_safety_zone(p_actual, obj_id, None, None):
+                                 collision_count += 1
+        
+        # 2. Check against other nets
+        self._ensure_dynamic_tree()
+        if self.dynamic_tree is not None:
+             tree_geoms = self.dynamic_tree.geometries
+             for comp in components:
+                  # Robust fallback chain to ensure crossings are caught even with zero clearance
+                  d_geoms = comp.dilated_actual_geometry or comp.dilated_geometry or comp.actual_geometry or comp.geometry
+                  if not d_geoms: continue
+                  
+                  # Ensure d_geoms is a list/array for STRtree.query
+                  if not isinstance(d_geoms, (list, tuple, numpy.ndarray)):
+                       d_geoms = [d_geoms]
+
+                  res_indices, tree_indices = self.dynamic_tree.query(d_geoms, predicate='intersects')
+                  if tree_indices.size > 0:
+                       hit_net_ids = numpy.take(self._dynamic_net_ids_array, tree_indices)
+                       net_id_str = str(net_id)
+                       
+                       comp_hits = []
+                       for i in range(len(tree_indices)):
+                            if hit_net_ids[i] == net_id_str: continue
+                            
+                            p_new = d_geoms[res_indices[i]]
+                            p_tree = tree_geoms[tree_indices[i]]
+                            if not p_new.touches(p_tree):
+                                 # Numerical tolerance for area overlap
+                                 if p_new.intersection(p_tree).area > 1e-7:
+                                      comp_hits.append(hit_net_ids[i])
+                       
+                       if comp_hits:
+                            collision_count += len(numpy.unique(comp_hits))
+
+        return (collision_count == 0), collision_count
+
+    def ray_cast(self, origin: Port, angle_deg: float, max_dist: float = 2000.0, net_width: float | None = None) -> float:
         rad = numpy.radians(angle_deg)
         cos_v, sin_v = numpy.cos(rad), numpy.sin(rad)
         dx, dy = max_dist * cos_v, max_dist * sin_v
         min_x, max_x = sorted([origin.x, origin.x + dx])
         min_y, max_y = sorted([origin.y, origin.y + dy])
+        
+        key = None
+        if net_width is not None:
+             tree = self._ensure_net_static_tree(net_width)
+             key = (round(net_width, 4), round(self.clearance, 4))
+             is_rect_arr = self._net_specific_is_rect[key]
+             bounds_arr = self._net_specific_bounds[key]
+        else:
              self._ensure_static_tree()
-        if self.static_tree is None: return max_dist
-        candidates = self.static_tree.query(box(min_x, min_y, max_x, max_y))
+             tree = self.static_tree
+             is_rect_arr = self._static_is_rect_array
+             bounds_arr = self._static_bounds_array
+
+        if tree is None: return max_dist
+        candidates = tree.query(box(min_x, min_y, max_x, max_y))
         if candidates.size == 0: return max_dist
+        
         min_dist = max_dist
         inv_dx = 1.0 / dx if abs(dx) > 1e-12 else 1e30
         inv_dy = 1.0 / dy if abs(dy) > 1e-12 else 1e30
-        b_arr = self._static_bounds_array[candidates]
-        dist_sq = (b_arr[:, 0] - origin.x)**2 + (b_arr[:, 1] - origin.y)**2
-        sorted_indices = numpy.argsort(dist_sq)
+        
+        tree_geoms = tree.geometries
         ray_line = None
-        for i in sorted_indices:
-            c = candidates[i]; b = self._static_bounds_array[c]
-            if abs(dx) < 1e-12:
+        
+        # Fast AABB-based pre-sort
+        candidates_bounds = bounds_arr[candidates]
+        # Distance to AABB min corner as heuristic
+        dist_sq = (candidates_bounds[:, 0] - origin.x)**2 + (candidates_bounds[:, 1] - origin.y)**2
+        sorted_indices = numpy.argsort(dist_sq)
+        
+        for idx in sorted_indices:
+            c = candidates[idx]
+            b = bounds_arr[c]
+            
+            # Fast axis-aligned ray-AABB intersection
+            # (Standard Slab method)
+            if abs(dx) < 1e-12: # Vertical ray
                 if origin.x < b[0] or origin.x > b[2]: tx_min, tx_max = 1e30, -1e30
                 else: tx_min, tx_max = -1e30, 1e30
             else:
                 t1, t2 = (b[0] - origin.x) * inv_dx, (b[2] - origin.x) * inv_dx
                 tx_min, tx_max = min(t1, t2), max(t1, t2)
-            if abs(dy) < 1e-12:
+                
+            if abs(dy) < 1e-12: # Horizontal ray
                 if origin.y < b[1] or origin.y > b[3]: ty_min, ty_max = 1e30, -1e30
                 else: ty_min, ty_max = -1e30, 1e30
             else:
                 t1, t2 = (b[1] - origin.y) * inv_dy, (b[3] - origin.y) * inv_dy
                 ty_min, ty_max = min(t1, t2), max(t1, t2)
+                
             t_min, t_max = max(tx_min, ty_min), min(tx_max, ty_max)
-            if t_max < 0 or t_min > t_max or t_min > 1.0 or t_min >= min_dist / max_dist: continue
-            if self._static_is_rect_array[c]:
-                min_dist = max(0.0, t_min * max_dist); continue
-            if ray_line is None: ray_line = LineString([(origin.x, origin.y), (origin.x + dx, origin.y + dy)])
-            obj_id = self.static_obj_ids[c]
-            if self.static_prepared[obj_id].intersects(ray_line):
-                intersection = ray_line.intersection(self.static_dilated[obj_id])
+            
+            # Intersection conditions
+            if t_max < 0 or t_min > t_max or t_min > 1.0: continue
+            
+            # If hit is further than current min_dist, skip
+            if t_min * max_dist >= min_dist: continue
+            
+            # HIGH PRECISION CHECK
+            if is_rect_arr[c]:
+                # Rectangles are perfectly described by their AABB
+                min_dist = max(0.0, t_min * max_dist)
+                continue
+            
+            # Fallback to full geometry check for non-rectangles (arcs, etc.)
+            if ray_line is None: 
+                ray_line = LineString([(origin.x, origin.y), (origin.x + dx, origin.y + dy)])
+            
+            obs_dilated = tree_geoms[c]
+            if obs_dilated.intersects(ray_line):
+                intersection = ray_line.intersection(obs_dilated)
                 if intersection.is_empty: continue
+                
                 def get_dist(geom):
                     if hasattr(geom, 'geoms'): return min(get_dist(g) for g in geom.geoms)
                     return numpy.sqrt((geom.coords[0][0] - origin.x)**2 + (geom.coords[0][1] - origin.y)**2)
+                
                 d = get_dist(intersection)
                 if d < min_dist: min_dist = d
+                
         return min_dist

inire/geometry/components.py

@@ -1,326 +1,105 @@
 from __future__ import annotations
 
-import math
-from typing import Literal, cast, Any
+from typing import Literal
+
 import numpy
-import shapely
-from shapely.geometry import Polygon, box, MultiPolygon
-from shapely.ops import unary_union
-from shapely.affinity import translate
+from shapely.affinity import translate as shapely_translate
+from shapely.geometry import Polygon, box
 
-from inire.constants import DEFAULT_SEARCH_GRID_SNAP_UM, TOLERANCE_LINEAR, TOLERANCE_ANGULAR
-from .primitives import Port
+from inire.constants import TOLERANCE_ANGULAR, TOLERANCE_LINEAR
+from .primitives import Port, rotation_matrix2
 
 
-def snap_search_grid(value: float, snap_size: float = DEFAULT_SEARCH_GRID_SNAP_UM) -> float:
-    """
-    Snap a coordinate to the nearest search grid unit.
-    """
-    return round(value / snap_size) * snap_size
+def _normalize_length(value: float) -> float:
+    return float(value)
 
 
 class ComponentResult:
-    """
-    Standard container for generated move geometry and state.
-    Supports Lazy Evaluation for translation to improve performance.
-    """
     __slots__ = (
-        '_geometry', '_dilated_geometry', '_proxy_geometry', '_actual_geometry', '_dilated_actual_geometry',
-        'end_port', 'length', 'move_type', '_bounds', '_dilated_bounds', 
-        '_total_bounds', '_total_dilated_bounds', '_bounds_cached', '_total_geom_list', '_offsets', '_coords_cache',
-        '_base_result', '_offset', 'rel_gx', 'rel_gy', 'rel_go'
+        "geometry",
+        "dilated_geometry",
+        "proxy_geometry",
+        "actual_geometry",
+        "dilated_actual_geometry",
+        "end_port",
+        "length",
+        "move_type",
+        "_bounds",
+        "_total_bounds",
+        "_dilated_bounds",
+        "_total_dilated_bounds",
     )
 
     def __init__(
         self,
-            geometry: list[Polygon] | None = None,
-            end_port: Port | None = None,
-            length: float = 0.0,
+        geometry: list[Polygon],
+        end_port: Port,
+        length: float,
+        move_type: str,
         dilated_geometry: list[Polygon] | None = None,
         proxy_geometry: list[Polygon] | None = None,
         actual_geometry: list[Polygon] | None = None,
         dilated_actual_geometry: list[Polygon] | None = None,
-            skip_bounds: bool = False,
-            move_type: str = 'Unknown',
-            _total_geom_list: list[Polygon] | None = None,
-            _offsets: list[int] | None = None,
-            _coords_cache: numpy.ndarray | None = None,
-            _base_result: ComponentResult | None = None,
-            _offset: tuple[float, float] | None = None,
-            snap_size: float = DEFAULT_SEARCH_GRID_SNAP_UM,
-            rel_gx: int | None = None,
-            rel_gy: int | None = None,
-            rel_go: int | None = None
     ) -> None:
+        self.geometry = geometry
+        self.dilated_geometry = dilated_geometry
+        self.proxy_geometry = proxy_geometry
+        self.actual_geometry = actual_geometry
+        self.dilated_actual_geometry = dilated_actual_geometry
         self.end_port = end_port
-        self.length = length
+        self.length = float(length)
         self.move_type = move_type
 
-        self._base_result = _base_result
-        self._offset = _offset
-        self._bounds_cached = False
+        self._bounds = [poly.bounds for poly in self.geometry]
+        self._total_bounds = _combine_bounds(self._bounds)
 
-        if rel_gx is not None:
-             self.rel_gx = rel_gx
-             self.rel_gy = rel_gy
-             self.rel_go = rel_go
-        elif end_port:
-             inv_snap = 1.0 / snap_size
-             self.rel_gx = int(round(end_port.x * inv_snap))
-             self.rel_gy = int(round(end_port.y * inv_snap))
-             self.rel_go = int(round(end_port.orientation))
-        else:
-             self.rel_gx = 0; self.rel_gy = 0; self.rel_go = 0
-
-        if _base_result is not None:
-            # Lazy Mode
-            self._geometry = None
-            self._dilated_geometry = None
-            self._proxy_geometry = None
-            self._actual_geometry = None
-            self._dilated_actual_geometry = None
-            self._bounds = None
-            self._dilated_bounds = None
-            self._total_bounds = None
-            self._total_dilated_bounds = None
-        else:
-            # Eager Mode (Base Component)
-            self._geometry = geometry
-            self._dilated_geometry = dilated_geometry
-            self._proxy_geometry = proxy_geometry
-            self._actual_geometry = actual_geometry
-            self._dilated_actual_geometry = dilated_actual_geometry
-            
-            # These are mostly legacy/unused but kept for slot safety
-            self._total_geom_list = _total_geom_list
-            self._offsets = _offsets
-            self._coords_cache = _coords_cache
-
-            if not skip_bounds and geometry:
-                # Use plain tuples for bounds to avoid NumPy overhead
-                self._bounds = [p.bounds for p in geometry]
-                b0 = self._bounds[0]
-                minx, miny, maxx, maxy = b0
-                for i in range(1, len(self._bounds)):
-                    b = self._bounds[i]
-                    if b[0] < minx: minx = b[0]
-                    if b[1] < miny: miny = b[1]
-                    if b[2] > maxx: maxx = b[2]
-                    if b[3] > maxy: maxy = b[3]
-                self._total_bounds = (minx, miny, maxx, maxy)
-                
-                if dilated_geometry is not None:
-                    self._dilated_bounds = [p.bounds for p in dilated_geometry]
-                    b0 = self._dilated_bounds[0]
-                    minx, miny, maxx, maxy = b0
-                    for i in range(1, len(self._dilated_bounds)):
-                        b = self._dilated_bounds[i]
-                        if b[0] < minx: minx = b[0]
-                        if b[1] < miny: miny = b[1]
-                        if b[2] > maxx: maxx = b[2]
-                        if b[3] > maxy: maxy = b[3]
-                    self._total_dilated_bounds = (minx, miny, maxx, maxy)
-                else:
+        if self.dilated_geometry is None:
             self._dilated_bounds = None
             self._total_dilated_bounds = None
         else:
-                self._bounds = None
-                self._total_bounds = None
-                self._dilated_bounds = None
-                self._total_dilated_bounds = None
-            self._bounds_cached = True
-
-    def _ensure_evaluated(self, attr_name: str) -> None:
-        if self._base_result is None:
-            return
-
-        # Check if specific attribute is already translated
-        internal_name = f'_{attr_name}'
-        if getattr(self, internal_name) is not None:
-            return
-
-        # Perform Translation for the specific attribute only
-        base_geoms = getattr(self._base_result, internal_name)
-        if base_geoms is None:
-            return
-
-        dx, dy = self._offset
-        # Use shapely.affinity.translate (imported at top level)
-        translated_geoms = [translate(p, dx, dy) for p in base_geoms]
-        setattr(self, internal_name, translated_geoms)
-
-    @property
-    def geometry(self) -> list[Polygon]:
-        self._ensure_evaluated('geometry')
-        return self._geometry
-
-    @property
-    def dilated_geometry(self) -> list[Polygon] | None:
-        self._ensure_evaluated('dilated_geometry')
-        return self._dilated_geometry
-
-    @property
-    def proxy_geometry(self) -> list[Polygon] | None:
-        self._ensure_evaluated('proxy_geometry')
-        return self._proxy_geometry
-
-    @property
-    def actual_geometry(self) -> list[Polygon] | None:
-        self._ensure_evaluated('actual_geometry')
-        return self._actual_geometry
-        
-    @property
-    def dilated_actual_geometry(self) -> list[Polygon] | None:
-        self._ensure_evaluated('dilated_actual_geometry')
-        return self._dilated_actual_geometry
+            self._dilated_bounds = [poly.bounds for poly in self.dilated_geometry]
+            self._total_dilated_bounds = _combine_bounds(self._dilated_bounds)
 
     @property
     def bounds(self) -> list[tuple[float, float, float, float]]:
-        if not self._bounds_cached:
-            self._ensure_bounds_evaluated()
         return self._bounds
 
     @property
     def total_bounds(self) -> tuple[float, float, float, float]:
-        if not self._bounds_cached:
-            self._ensure_bounds_evaluated()
         return self._total_bounds
 
     @property
     def dilated_bounds(self) -> list[tuple[float, float, float, float]] | None:
-        if not self._bounds_cached:
-            self._ensure_bounds_evaluated()
         return self._dilated_bounds
 
     @property
     def total_dilated_bounds(self) -> tuple[float, float, float, float] | None:
-        if not self._bounds_cached:
-            self._ensure_bounds_evaluated()
         return self._total_dilated_bounds
 
-    def _ensure_bounds_evaluated(self) -> None:
-        if self._bounds_cached: return
-        base = self._base_result
-        if base is not None:
-             dx, dy = self._offset
-             # Direct tuple creation is much faster than NumPy for single AABBs
-             if base._bounds is not None:
-                  self._bounds = [(b[0]+dx, b[1]+dy, b[2]+dx, b[3]+dy) for b in base._bounds]
-             if base._total_bounds is not None:
-                  b = base._total_bounds
-                  self._total_bounds = (b[0]+dx, b[1]+dy, b[2]+dx, b[3]+dy)
-             if base._dilated_bounds is not None:
-                  self._dilated_bounds = [(b[0]+dx, b[1]+dy, b[2]+dx, b[3]+dy) for b in base._dilated_bounds]
-             if base._total_dilated_bounds is not None:
-                  b = base._total_dilated_bounds
-                  self._total_dilated_bounds = (b[0]+dx, b[1]+dy, b[2]+dx, b[3]+dy)
-        self._bounds_cached = True
-
-    def translate(self, dx: float, dy: float, rel_gx: int | None = None, rel_gy: int | None = None, rel_go: int | None = None) -> ComponentResult:
-        """
-        Create a new ComponentResult translated by (dx, dy).
-        """
-        new_port = Port(self.end_port.x + dx, self.end_port.y + dy, self.end_port.orientation, snap=False)
-        
-        # LAZY TRANSLATE
-        if self._base_result:
-             base = self._base_result
-             current_offset = self._offset
-             new_offset = (current_offset[0] + dx, current_offset[1] + dy)
-        else:
-             base = self
-             new_offset = (dx, dy)
-
+    def translate(self, dx: int | float, dy: int | float) -> ComponentResult:
         return ComponentResult(
-            end_port=new_port,
+            geometry=[shapely_translate(poly, dx, dy) for poly in self.geometry],
+            end_port=self.end_port + [dx, dy, 0],
             length=self.length,
             move_type=self.move_type,
-            _base_result=base,
-            _offset=new_offset,
-            rel_gx=rel_gx,
-            rel_gy=rel_gy,
-            rel_go=rel_go
+            dilated_geometry=None if self.dilated_geometry is None else [shapely_translate(poly, dx, dy) for poly in self.dilated_geometry],
+            proxy_geometry=None if self.proxy_geometry is None else [shapely_translate(poly, dx, dy) for poly in self.proxy_geometry],
+            actual_geometry=None if self.actual_geometry is None else [shapely_translate(poly, dx, dy) for poly in self.actual_geometry],
+            dilated_actual_geometry=None if self.dilated_actual_geometry is None else [shapely_translate(poly, dx, dy) for poly in self.dilated_actual_geometry],
         )
 
 
-class Straight:
-    """
-    Move generator for straight waveguide segments.
-    """
-    @staticmethod
-    def generate(
-            start_port: Port,
-            length: float,
-            width: float,
-            snap_to_grid: bool = True,
-            dilation: float = 0.0,
-            snap_size: float = DEFAULT_SEARCH_GRID_SNAP_UM,
-            ) -> ComponentResult:
-        """
-        Generate a straight waveguide segment.
-        """
-        rad = numpy.radians(start_port.orientation)
-        cos_val = numpy.cos(rad)
-        sin_val = numpy.sin(rad)
-
-        ex = start_port.x + length * cos_val
-        ey = start_port.y + length * sin_val
-
-        if snap_to_grid:
-            ex = snap_search_grid(ex, snap_size)
-            ey = snap_search_grid(ey, snap_size)
-
-        end_port = Port(ex, ey, start_port.orientation)
-        actual_length = numpy.sqrt((end_port.x - start_port.x)**2 + (end_port.y - start_port.y)**2)
-
-        # Create polygons using vectorized points
-        half_w = width / 2.0
-        pts_raw = numpy.array([
-            [0, half_w], 
-            [actual_length, half_w], 
-            [actual_length, -half_w], 
-            [0, -half_w]
-        ])
-        
-        # Rotation matrix (standard 2D rotation)
-        rot_matrix = numpy.array([[cos_val, -sin_val], [sin_val, cos_val]])
-        
-        # Transform points: P' = R * P + T
-        poly_points = (pts_raw @ rot_matrix.T) + [start_port.x, start_port.y]
-        geom = [Polygon(poly_points)]
-
-        dilated_geom = None
-        if dilation > 0:
-            # Direct calculation of dilated rectangle instead of expensive buffer()
-            half_w_dil = half_w + dilation
-            pts_dil = numpy.array([
-                [-dilation, half_w_dil], 
-                [actual_length + dilation, half_w_dil], 
-                [actual_length + dilation, -half_w_dil], 
-                [-dilation, -half_w_dil]
-            ])
-            poly_points_dil = (pts_dil @ rot_matrix.T) + [start_port.x, start_port.y]
-            dilated_geom = [Polygon(poly_points_dil)]
-
-        # Pre-calculate grid indices for faster ComponentResult init
-        inv_snap = 1.0 / snap_size
-        rgx = int(round(ex * inv_snap))
-        rgy = int(round(ey * inv_snap))
-        rgo = int(round(start_port.orientation))
-
-        # For straight segments, geom IS the actual geometry
-        return ComponentResult(
-            geometry=geom, end_port=end_port, length=actual_length, 
-            dilated_geometry=dilated_geom, actual_geometry=geom, 
-            dilated_actual_geometry=dilated_geom, move_type='Straight', 
-            snap_size=snap_size, rel_gx=rgx, rel_gy=rgy, rel_go=rgo
+def _combine_bounds(bounds_list: list[tuple[float, float, float, float]]) -> tuple[float, float, float, float]:
+    arr = numpy.asarray(bounds_list, dtype=numpy.float64)
+    return (
+        float(arr[:, 0].min()),
+        float(arr[:, 1].min()),
+        float(arr[:, 2].max()),
+        float(arr[:, 3].max()),
     )
 
 
 def _get_num_segments(radius: float, angle_deg: float, sagitta: float = 0.01) -> int:
-    """
-    Calculate number of segments for an arc to maintain a maximum sagitta.
-    """
     if radius <= 0:
         return 1
     ratio = max(0.0, min(1.0, 1.0 - sagitta / radius))
@@ -332,86 +111,35 @@ def _get_num_segments(radius: float, angle_deg: float, sagitta: float = 0.01) ->
 
 
 def _get_arc_polygons(
-        cx: float,
-        cy: float,
+    cxy: tuple[float, float],
     radius: float,
     width: float,
-        t_start: float,
-        t_end: float,
+    ts: tuple[float, float],
     sagitta: float = 0.01,
     dilation: float = 0.0,
 ) -> list[Polygon]:
-    """
-    Helper to generate arc-shaped polygons using vectorized NumPy operations.
-    """
-    num_segments = _get_num_segments(radius, float(numpy.degrees(abs(t_end - t_start))), sagitta)
+    t_start, t_end = numpy.radians(ts[0]), numpy.radians(ts[1])
+    num_segments = _get_num_segments(radius, abs(ts[1] - ts[0]), sagitta)
     angles = numpy.linspace(t_start, t_end, num_segments + 1)
 
+    cx, cy = cxy
+    inner_radius = radius - width / 2.0 - dilation
+    outer_radius = radius + width / 2.0 + dilation
+
     cos_a = numpy.cos(angles)
     sin_a = numpy.sin(angles)
 
-    inner_radius = radius - width / 2.0 - dilation
-    outer_radius = radius + width / 2.0 + dilation
-    
-    inner_points = numpy.stack([cx + inner_radius * cos_a, cy + inner_radius * sin_a], axis=1)
-    outer_points = numpy.stack([cx + outer_radius * cos_a[::-1], cy + outer_radius * sin_a[::-1]], axis=1)
-    
-    # Concatenate inner and outer points to form the polygon ring
-    poly_points = numpy.concatenate([inner_points, outer_points])
-    
-    return [Polygon(poly_points)]
+    inner_points = numpy.column_stack((cx + inner_radius * cos_a, cy + inner_radius * sin_a))
+    outer_points = numpy.column_stack((cx + outer_radius * cos_a[::-1], cy + outer_radius * sin_a[::-1]))
+    return [Polygon(numpy.concatenate((inner_points, outer_points), axis=0))]
 
 
-def _clip_bbox(
-        cx: float,
-        cy: float,
-        radius: float,
-        width: float,
-        t_start: float,
-        t_end: float,
-        ) -> Polygon:
-    """
-    Generates a rotationally invariant bounding polygon for an arc.
-    """
-    sweep = abs(t_end - t_start)
-    if sweep > 2 * numpy.pi:
-        sweep = sweep % (2 * numpy.pi)
-    
-    mid_angle = (t_start + t_end) / 2.0
-    # Handle wrap-around for mid_angle
-    if abs(t_end - t_start) > numpy.pi:
-        mid_angle += numpy.pi
-        
-    r_out = radius + width / 2.0
-    r_in = max(0.0, radius - width / 2.0)
-    
-    half_sweep = sweep / 2.0
-    
-    # Define vertices in local space (center at 0,0, symmetry axis along +X)
-    cos_hs = numpy.cos(half_sweep)
-    cos_hs2 = numpy.cos(half_sweep / 2.0)
-    
-    # Distance to peak from center: r_out / cos(hs/2)
-    peak_r = r_out / cos_hs2
-    
-    local_verts = [
-        [r_in * numpy.cos(-half_sweep), r_in * numpy.sin(-half_sweep)],
-        [r_out * numpy.cos(-half_sweep), r_out * numpy.sin(-half_sweep)],
-        [peak_r * numpy.cos(-half_sweep/2), peak_r * numpy.sin(-half_sweep/2)],
-        [peak_r * numpy.cos(half_sweep/2), peak_r * numpy.sin(half_sweep/2)],
-        [r_out * numpy.cos(half_sweep), r_out * numpy.sin(half_sweep)],
-        [r_in * numpy.cos(half_sweep), r_in * numpy.sin(half_sweep)],
-        [r_in, 0.0]
-    ]
-    
-    # Rotate and translate to world space
-    cos_m = numpy.cos(mid_angle)
-    sin_m = numpy.sin(mid_angle)
-    rot = numpy.array([[cos_m, -sin_m], [sin_m, cos_m]])
-    
-    world_verts = (numpy.array(local_verts) @ rot.T) + [cx, cy]
-    
-    return Polygon(world_verts)
+def _clip_bbox(cxy: tuple[float, float], radius: float, width: float, ts: tuple[float, float], clip_margin: float) -> Polygon:
+    arc_poly = _get_arc_polygons(cxy, radius, width, ts)[0]
+    minx, miny, maxx, maxy = arc_poly.bounds
+    bbox_poly = box(minx, miny, maxx, maxy)
+    shrink = min(clip_margin, max(radius, width))
+    return bbox_poly.buffer(-shrink, join_style=2) if shrink > 0 else bbox_poly
 
 
 def _apply_collision_model(
@@ -419,39 +147,57 @@ def _apply_collision_model(
     collision_type: Literal["arc", "bbox", "clipped_bbox"] | Polygon,
     radius: float,
     width: float,
-        cx: float = 0.0,
-        cy: float = 0.0,
-        clip_margin: float = 10.0,
-        t_start: float | None = None,
-        t_end: float | None = None,
+    cxy: tuple[float, float],
+    clip_margin: float,
+    ts: tuple[float, float],
 ) -> list[Polygon]:
-    """
-    Applies the specified collision model to an arc geometry.
-    """
     if isinstance(collision_type, Polygon):
-        # Translate the custom polygon to the bend center (cx, cy)
-        return [shapely.transform(collision_type, lambda x: x + [cx, cy])]
-
+        return [shapely_translate(collision_type, cxy[0], cxy[1])]
     if collision_type == "arc":
         return [arc_poly]
+    if collision_type == "clipped_bbox":
+        clipped = _clip_bbox(cxy, radius, width, ts, clip_margin)
+        return [clipped if not clipped.is_empty else box(*arc_poly.bounds)]
+    return [box(*arc_poly.bounds)]
 
-    if collision_type == "clipped_bbox" and t_start is not None and t_end is not None:
-        return [_clip_bbox(cx, cy, radius, width, t_start, t_end)]
 
-    # Bounding box of the high-fidelity arc (fallback for bbox or missing angles)
-    minx, miny, maxx, maxy = arc_poly.bounds
-    bbox_poly = box(minx, miny, maxx, maxy)
+class Straight:
+    @staticmethod
+    def generate(
+        start_port: Port,
+        length: float,
+        width: float,
+        dilation: float = 0.0,
+    ) -> ComponentResult:
+        rot2 = rotation_matrix2(start_port.r)
+        length_f = _normalize_length(length)
+        disp = rot2 @ numpy.array((length_f, 0.0))
+        end_port = Port(start_port.x + disp[0], start_port.y + disp[1], start_port.r)
 
-    if collision_type == "bbox":
-        return [bbox_poly]
+        half_w = width / 2.0
+        pts = numpy.array(((0.0, half_w), (length_f, half_w), (length_f, -half_w), (0.0, -half_w)))
+        poly_points = (pts @ rot2.T) + numpy.array((start_port.x, start_port.y))
+        geometry = [Polygon(poly_points)]
 
-    return [arc_poly]
+        dilated_geometry = None
+        if dilation > 0:
+            half_w_d = half_w + dilation
+            pts_d = numpy.array(((-dilation, half_w_d), (length_f + dilation, half_w_d), (length_f + dilation, -half_w_d), (-dilation, -half_w_d)))
+            poly_points_d = (pts_d @ rot2.T) + numpy.array((start_port.x, start_port.y))
+            dilated_geometry = [Polygon(poly_points_d)]
+
+        return ComponentResult(
+            geometry=geometry,
+            end_port=end_port,
+            length=abs(length_f),
+            move_type="Straight",
+            dilated_geometry=dilated_geometry,
+            actual_geometry=geometry,
+            dilated_actual_geometry=dilated_geometry,
+        )
 
 
 class Bend90:
-    """
-    Move generator for 90-degree waveguide bends.
-    """
     @staticmethod
     def generate(
         start_port: Port,
@@ -462,103 +208,62 @@ class Bend90:
         collision_type: Literal["arc", "bbox", "clipped_bbox"] | Polygon = "arc",
         clip_margin: float = 10.0,
         dilation: float = 0.0,
-            snap_to_grid: bool = True,
-            snap_size: float = DEFAULT_SEARCH_GRID_SNAP_UM,
     ) -> ComponentResult:
-        """
-        Generate a 90-degree bend.
-        """
-        rad_start = numpy.radians(start_port.orientation)
+        rot2 = rotation_matrix2(start_port.r)
+        sign = 1 if direction == "CCW" else -1
 
-        # Center of the arc
-        if direction == "CCW":
-            cx = start_port.x + radius * numpy.cos(rad_start + numpy.pi / 2)
-            cy = start_port.y + radius * numpy.sin(rad_start + numpy.pi / 2)
-            t_start = rad_start - numpy.pi / 2
-            t_end = t_start + numpy.pi / 2
-            new_ori = (start_port.orientation + 90) % 360
-        else:
-            cx = start_port.x + radius * numpy.cos(rad_start - numpy.pi / 2)
-            cy = start_port.y + radius * numpy.sin(rad_start - numpy.pi / 2)
-            t_start = rad_start + numpy.pi / 2
-            t_end = t_start - numpy.pi / 2
-            new_ori = (start_port.orientation - 90) % 360
+        center_local = numpy.array((0.0, sign * radius))
+        end_local = numpy.array((radius, sign * radius))
+        center_xy = (rot2 @ center_local) + numpy.array((start_port.x, start_port.y))
+        end_xy = (rot2 @ end_local) + numpy.array((start_port.x, start_port.y))
+        end_port = Port(end_xy[0], end_xy[1], start_port.r + sign * 90)
 
-        # Snap the end point to the grid
-        ex_raw = cx + radius * numpy.cos(t_end)
-        ey_raw = cy + radius * numpy.sin(t_end)
+        start_theta = start_port.r - sign * 90
+        end_theta = start_port.r
+        ts = (float(start_theta), float(end_theta))
 
-        if snap_to_grid:
-            ex = snap_search_grid(ex_raw, snap_size)
-            ey = snap_search_grid(ey_raw, snap_size)
-        else:
-            ex, ey = ex_raw, ey_raw
-        
-        # Slightly adjust radius and t_end to hit snapped point exactly
-        dx, dy = ex - cx, ey - cy
-        actual_radius = numpy.sqrt(dx**2 + dy**2)
-        
-        t_end_snapped = numpy.arctan2(dy, dx)
-        # Ensure directionality and approx 90 degree sweep
-        if direction == "CCW":
-            while t_end_snapped <= t_start:
-                t_end_snapped += 2 * numpy.pi
-            while t_end_snapped > t_start + numpy.pi:
-                t_end_snapped -= 2 * numpy.pi
-        else:
-            while t_end_snapped >= t_start:
-                t_end_snapped -= 2 * numpy.pi
-            while t_end_snapped < t_start - numpy.pi:
-                t_end_snapped += 2 * numpy.pi
-        t_end = t_end_snapped
-
-        end_port = Port(ex, ey, new_ori)
-
-        arc_polys = _get_arc_polygons(cx, cy, actual_radius, width, t_start, t_end, sagitta)
+        arc_polys = _get_arc_polygons((float(center_xy[0]), float(center_xy[1])), radius, width, ts, sagitta)
         collision_polys = _apply_collision_model(
-            arc_polys[0], collision_type, actual_radius, width, cx, cy, clip_margin, t_start, t_end
+            arc_polys[0],
+            collision_type,
+            radius,
+            width,
+            (float(center_xy[0]), float(center_xy[1])),
+            clip_margin,
+            ts,
         )
 
-        proxy_geom = None
+        proxy_geometry = None
         if collision_type == "arc":
-            # Auto-generate a clipped_bbox proxy for tiered collision checks
-            proxy_geom = _apply_collision_model(
-                arc_polys[0], "clipped_bbox", actual_radius, width, cx, cy, clip_margin, t_start, t_end
+            proxy_geometry = _apply_collision_model(
+                arc_polys[0],
+                "clipped_bbox",
+                radius,
+                width,
+                (float(center_xy[0]), float(center_xy[1])),
+                clip_margin,
+                ts,
             )
 
-        dilated_geom = None
-        dilated_actual_geom = None
+        dilated_actual_geometry = None
+        dilated_geometry = None
         if dilation > 0:
-            dilated_actual_geom = _get_arc_polygons(cx, cy, actual_radius, width, t_start, t_end, sagitta, dilation=dilation)
-            if collision_type == "arc":
-                dilated_geom = dilated_actual_geom
-            else:
-                dilated_geom = [p.buffer(dilation) for p in collision_polys]
-
-        # Pre-calculate grid indices for faster ComponentResult init
-        inv_snap = 1.0 / snap_size
-        rgx = int(round(ex * inv_snap))
-        rgy = int(round(ey * inv_snap))
-        rgo = int(round(new_ori))
+            dilated_actual_geometry = _get_arc_polygons((float(center_xy[0]), float(center_xy[1])), radius, width, ts, sagitta, dilation=dilation)
+            dilated_geometry = dilated_actual_geometry if collision_type == "arc" else [poly.buffer(dilation) for poly in collision_polys]
 
         return ComponentResult(
             geometry=collision_polys,
             end_port=end_port,
-            length=actual_radius * numpy.abs(t_end - t_start),
-            dilated_geometry=dilated_geom,
-            proxy_geometry=proxy_geom,
+            length=abs(radius) * numpy.pi / 2.0,
+            move_type="Bend90",
+            dilated_geometry=dilated_geometry,
+            proxy_geometry=proxy_geometry,
             actual_geometry=arc_polys,
-            dilated_actual_geometry=dilated_actual_geom,
-            move_type='Bend90',
-            snap_size=snap_size,
-            rel_gx=rgx, rel_gy=rgy, rel_go=rgo
+            dilated_actual_geometry=dilated_actual_geometry,
         )
 
 
 class SBend:
-    """
-    Move generator for parametric S-bends.
-    """
     @staticmethod
     def generate(
         start_port: Port,
@@ -569,113 +274,60 @@ class SBend:
         collision_type: Literal["arc", "bbox", "clipped_bbox"] | Polygon = "arc",
         clip_margin: float = 10.0,
         dilation: float = 0.0,
-            snap_to_grid: bool = True,
-            snap_size: float = DEFAULT_SEARCH_GRID_SNAP_UM,
     ) -> ComponentResult:
-        """
-        Generate a parametric S-bend (two tangent arcs).
-        """
         if abs(offset) >= 2 * radius:
             raise ValueError(f"SBend offset {offset} must be less than 2*radius {2 * radius}")
 
-        theta_init = numpy.arccos(1 - abs(offset) / (2 * radius))
-        dx_init = 2 * radius * numpy.sin(theta_init)
-        rad_start = numpy.radians(start_port.orientation)
+        sign = 1 if offset >= 0 else -1
+        theta = numpy.arccos(1.0 - abs(offset) / (2.0 * radius))
+        dx = 2.0 * radius * numpy.sin(theta)
+        theta_deg = float(numpy.degrees(theta))
 
-        # Target point
-        ex_raw = start_port.x + dx_init * numpy.cos(rad_start) - offset * numpy.sin(rad_start)
-        ey_raw = start_port.y + dx_init * numpy.sin(rad_start) + offset * numpy.cos(rad_start)
+        rot2 = rotation_matrix2(start_port.r)
+        end_local = numpy.array((dx, offset))
+        end_xy = (rot2 @ end_local) + numpy.array((start_port.x, start_port.y))
+        end_port = Port(end_xy[0], end_xy[1], start_port.r)
 
-        if snap_to_grid:
-            ex = snap_search_grid(ex_raw, snap_size)
-            ey = snap_search_grid(ey_raw, snap_size)
-        else:
-            ex, ey = ex_raw, ey_raw
+        c1_local = numpy.array((0.0, sign * radius))
+        c2_local = numpy.array((dx, offset - sign * radius))
+        c1_xy = (rot2 @ c1_local) + numpy.array((start_port.x, start_port.y))
+        c2_xy = (rot2 @ c2_local) + numpy.array((start_port.x, start_port.y))
 
-        end_port = Port(ex, ey, start_port.orientation)
+        ts1 = (float(start_port.r - sign * 90), float(start_port.r - sign * 90 + sign * theta_deg))
+        second_base = start_port.r + (90 if sign > 0 else 270)
+        ts2 = (float(second_base + sign * theta_deg), float(second_base))
 
-        # Solve for theta and radius that hit (ex, ey) exactly
-        local_dx = (ex - start_port.x) * numpy.cos(rad_start) + (ey - start_port.y) * numpy.sin(rad_start)
-        local_dy = -(ex - start_port.x) * numpy.sin(rad_start) + (ey - start_port.y) * numpy.cos(rad_start)
+        arc1 = _get_arc_polygons((float(c1_xy[0]), float(c1_xy[1])), radius, width, ts1, sagitta)[0]
+        arc2 = _get_arc_polygons((float(c2_xy[0]), float(c2_xy[1])), radius, width, ts2, sagitta)[0]
+        actual_geometry = [arc1, arc2]
+        geometry = [
+            _apply_collision_model(arc1, collision_type, radius, width, (float(c1_xy[0]), float(c1_xy[1])), clip_margin, ts1)[0],
+            _apply_collision_model(arc2, collision_type, radius, width, (float(c2_xy[0]), float(c2_xy[1])), clip_margin, ts2)[0],
+        ]
 
-        # tan(theta / 2) = local_dy / local_dx
-        theta = 2 * numpy.arctan2(abs(local_dy), local_dx)
-        
-        if abs(theta) < TOLERANCE_ANGULAR:
-             # De-generate to straight
-             actual_len = numpy.sqrt(local_dx**2 + local_dy**2)
-             return Straight.generate(start_port, actual_len, width, snap_to_grid=False, dilation=dilation, snap_size=snap_size)
-
-        denom = (2 * (1 - numpy.cos(theta)))
-        if abs(denom) < TOLERANCE_LINEAR:
-             raise ValueError("SBend calculation failed: radius denominator zero")
-             
-        actual_radius = abs(local_dy) / denom
-        
-        # Safety Check: Reject SBends with tiny radii that would cause self-overlap
-        if actual_radius < width:
-             raise ValueError(f"SBend actual_radius {actual_radius:.3f} is too small (width={width})")
-
-        # Limit radius to prevent giant arcs
-        if actual_radius > 100000.0:
-             actual_len = numpy.sqrt(local_dx**2 + local_dy**2)
-             return Straight.generate(start_port, actual_len, width, snap_to_grid=False, dilation=dilation, snap_size=snap_size)
-
-        direction = 1 if local_dy > 0 else -1
-        c1_angle = rad_start + direction * numpy.pi / 2
-        cx1 = start_port.x + actual_radius * numpy.cos(c1_angle)
-        cy1 = start_port.y + actual_radius * numpy.sin(c1_angle)
-        ts1, te1 = c1_angle + numpy.pi, c1_angle + numpy.pi + direction * theta
-
-        c2_angle = rad_start - direction * numpy.pi / 2
-        cx2 = ex + actual_radius * numpy.cos(c2_angle)
-        cy2 = ey + actual_radius * numpy.sin(c2_angle)
-        te2 = c2_angle + numpy.pi
-        ts2 = te2 + direction * theta
-
-        arc1 = _get_arc_polygons(cx1, cy1, actual_radius, width, ts1, te1, sagitta)[0]
-        arc2 = _get_arc_polygons(cx2, cy2, actual_radius, width, ts2, te2, sagitta)[0]
-        arc_polys = [arc1, arc2]
-
-        # Use the provided collision model for primary geometry
-        col1 = _apply_collision_model(arc1, collision_type, actual_radius, width, cx1, cy1, clip_margin, ts1, te1)[0]
-        col2 = _apply_collision_model(arc2, collision_type, actual_radius, width, cx2, cy2, clip_margin, ts2, te2)[0]
-        collision_polys = [col1, col2]
-
-        proxy_geom = None
+        proxy_geometry = None
         if collision_type == "arc":
-            # Auto-generate proxies
-            p1 = _apply_collision_model(arc1, "clipped_bbox", actual_radius, width, cx1, cy1, clip_margin, ts1, te1)[0]
-            p2 = _apply_collision_model(arc2, "clipped_bbox", actual_radius, width, cx2, cy2, clip_margin, ts2, te2)[0]
-            proxy_geom = [p1, p2]
+            proxy_geometry = [
+                _apply_collision_model(arc1, "clipped_bbox", radius, width, (float(c1_xy[0]), float(c1_xy[1])), clip_margin, ts1)[0],
+                _apply_collision_model(arc2, "clipped_bbox", radius, width, (float(c2_xy[0]), float(c2_xy[1])), clip_margin, ts2)[0],
+            ]
 
-        dilated_geom = None
-        dilated_actual_geom = None
+        dilated_actual_geometry = None
+        dilated_geometry = None
         if dilation > 0:
-            d1 = _get_arc_polygons(cx1, cy1, actual_radius, width, ts1, te1, sagitta, dilation=dilation)[0]
-            d2 = _get_arc_polygons(cx2, cy2, actual_radius, width, ts2, te2, sagitta, dilation=dilation)[0]
-            dilated_actual_geom = [d1, d2]
-            
-            if collision_type == "arc":
-                dilated_geom = dilated_actual_geom
-            else:
-                dilated_geom = [p.buffer(dilation) for p in collision_polys]
-
-        # Pre-calculate grid indices for faster ComponentResult init
-        inv_snap = 1.0 / snap_size
-        rgx = int(round(ex * inv_snap))
-        rgy = int(round(ey * inv_snap))
-        rgo = int(round(start_port.orientation))
+            dilated_actual_geometry = [
+                _get_arc_polygons((float(c1_xy[0]), float(c1_xy[1])), radius, width, ts1, sagitta, dilation=dilation)[0],
+                _get_arc_polygons((float(c2_xy[0]), float(c2_xy[1])), radius, width, ts2, sagitta, dilation=dilation)[0],
+            ]
+            dilated_geometry = dilated_actual_geometry if collision_type == "arc" else [poly.buffer(dilation) for poly in geometry]
 
         return ComponentResult(
-            geometry=collision_polys, 
+            geometry=geometry,
             end_port=end_port,
-            length=2 * actual_radius * theta,
-            dilated_geometry=dilated_geom,
-            proxy_geometry=proxy_geom,
-            actual_geometry=arc_polys,
-            dilated_actual_geometry=dilated_actual_geom,
-            move_type='SBend',
-            snap_size=snap_size,
-            rel_gx=rgx, rel_gy=rgy, rel_go=rgo
+            length=2.0 * radius * theta,
+            move_type="SBend",
+            dilated_geometry=dilated_geometry,
+            proxy_geometry=proxy_geometry,
+            actual_geometry=actual_geometry,
+            dilated_actual_geometry=dilated_actual_geometry,
         )

inire/geometry/primitives.py

@@ -1,77 +1,160 @@
 from __future__ import annotations
 
+from collections.abc import Iterator
+from typing import Self
+
 import numpy
+from numpy.typing import ArrayLike, NDArray
 
 
-# 1nm snap (0.001 µm)
-GRID_SNAP_UM = 0.001
+def _normalize_angle(angle_deg: int | float) -> int:
+    angle = int(round(angle_deg)) % 360
+    if angle % 90 != 0:
+        raise ValueError(f"Port angle must be Manhattan (multiple of 90), got {angle_deg!r}")
+    return angle
 
 
-def snap_nm(value: float) -> float:
-    """
-    Snap a coordinate to the nearest 1nm (0.001 um).
-    """
-    return round(value * 1000) / 1000
+def _as_int32_triplet(value: ArrayLike) -> NDArray[numpy.int32]:
+    arr = numpy.asarray(value, dtype=numpy.int32)
+    if arr.shape != (3,):
+        raise ValueError(f"Port array must have shape (3,), got {arr.shape}")
+    arr = arr.copy()
+    arr[2] = _normalize_angle(int(arr[2]))
+    return arr
 
 
-from inire.constants import TOLERANCE_LINEAR
-
 class Port:
     """
-    A port defined by (x, y, orientation) in micrometers.
+    Port represented as an ndarray-backed (x, y, r) triple with int32 storage.
     """
-    __slots__ = ('x', 'y', 'orientation')
 
-    def __init__(
-            self,
-            x: float,
-            y: float,
-            orientation: float,
-            snap: bool = True
-            ) -> None:
-        if snap:
-            self.x = round(x * 1000) / 1000
-            self.y = round(y * 1000) / 1000
-            # Faster orientation normalization for common cases
-            if 0 <= orientation < 360:
-                self.orientation = float(orientation)
-            else:
-                self.orientation = float(orientation % 360)
-        else:
-            self.x = x
-            self.y = y
-            self.orientation = float(orientation)
+    __slots__ = ("_xyr",)
+
+    def __init__(self, x: int | float, y: int | float, r: int | float) -> None:
+        self._xyr = numpy.array(
+            (int(round(x)), int(round(y)), _normalize_angle(r)),
+            dtype=numpy.int32,
+        )
+
+    @classmethod
+    def from_array(cls, xyr: ArrayLike) -> Self:
+        obj = cls.__new__(cls)
+        obj._xyr = _as_int32_triplet(xyr)
+        return obj
+
+    @property
+    def x(self) -> int:
+        return int(self._xyr[0])
+
+    @x.setter
+    def x(self, val: int | float) -> None:
+        self._xyr[0] = int(round(val))
+
+    @property
+    def y(self) -> int:
+        return int(self._xyr[1])
+
+    @y.setter
+    def y(self, val: int | float) -> None:
+        self._xyr[1] = int(round(val))
+
+    @property
+    def r(self) -> int:
+        return int(self._xyr[2])
+
+    @r.setter
+    def r(self, val: int | float) -> None:
+        self._xyr[2] = _normalize_angle(val)
+
+    @property
+    def orientation(self) -> int:
+        return self.r
+
+    @orientation.setter
+    def orientation(self, val: int | float) -> None:
+        self.r = val
+
+    @property
+    def xyr(self) -> NDArray[numpy.int32]:
+        return self._xyr
+
+    @xyr.setter
+    def xyr(self, val: ArrayLike) -> None:
+        self._xyr = _as_int32_triplet(val)
 
     def __repr__(self) -> str:
-        return f'Port(x={self.x}, y={self.y}, orientation={self.orientation})'
+        return f"Port(x={self.x}, y={self.y}, r={self.r})"
+
+    def __iter__(self) -> Iterator[int]:
+        return iter((self.x, self.y, self.r))
+
+    def __len__(self) -> int:
+        return 3
+
+    def __getitem__(self, item: int | slice) -> int | NDArray[numpy.int32]:
+        return self._xyr[item]
+
+    def __array__(self, dtype: numpy.dtype | None = None) -> NDArray[numpy.int32]:
+        return numpy.asarray(self._xyr, dtype=dtype)
 
     def __eq__(self, other: object) -> bool:
         if not isinstance(other, Port):
             return False
-        return (abs(self.x - other.x) < TOLERANCE_LINEAR and
-                abs(self.y - other.y) < TOLERANCE_LINEAR and
-                abs(self.orientation - other.orientation) < TOLERANCE_LINEAR)
+        return bool(numpy.array_equal(self._xyr, other._xyr))
 
     def __hash__(self) -> int:
-        return hash((round(self.x, 6), round(self.y, 6), round(self.orientation, 6)))
+        return hash(self.as_tuple())
+
+    def copy(self) -> Self:
+        return type(self).from_array(self._xyr.copy())
+
+    def as_tuple(self) -> tuple[int, int, int]:
+        return (self.x, self.y, self.r)
+
+    def translate(self, dxy: ArrayLike) -> Self:
+        dxy_arr = numpy.asarray(dxy, dtype=numpy.int32)
+        if dxy_arr.shape == (2,):
+            return type(self)(self.x + int(dxy_arr[0]), self.y + int(dxy_arr[1]), self.r)
+        if dxy_arr.shape == (3,):
+            return type(self)(self.x + int(dxy_arr[0]), self.y + int(dxy_arr[1]), self.r + int(dxy_arr[2]))
+        raise ValueError(f"Translation must have shape (2,) or (3,), got {dxy_arr.shape}")
+
+    def __add__(self, other: ArrayLike) -> Self:
+        return self.translate(other)
+
+    def __sub__(self, other: ArrayLike | Self) -> NDArray[numpy.int32]:
+        if isinstance(other, Port):
+            return self._xyr - other._xyr
+        return self._xyr - numpy.asarray(other, dtype=numpy.int32)
 
 
-def translate_port(port: Port, dx: float, dy: float) -> Port:
-    """
-    Translate a port by (dx, dy).
-    """
-    return Port(port.x + dx, port.y + dy, port.orientation)
+ROT2_0 = numpy.array(((1, 0), (0, 1)), dtype=numpy.int32)
+ROT2_90 = numpy.array(((0, -1), (1, 0)), dtype=numpy.int32)
+ROT2_180 = numpy.array(((-1, 0), (0, -1)), dtype=numpy.int32)
+ROT2_270 = numpy.array(((0, 1), (-1, 0)), dtype=numpy.int32)
 
 
-def rotate_port(port: Port, angle: float, origin: tuple[float, float] = (0, 0)) -> Port:
-    """
-    Rotate a port by a multiple of 90 degrees around an origin.
-    """
-    ox, oy = origin
-    px, py = port.x, port.y
+def rotation_matrix2(rotation_deg: int) -> NDArray[numpy.int32]:
+    quadrant = (_normalize_angle(rotation_deg) // 90) % 4
+    return (ROT2_0, ROT2_90, ROT2_180, ROT2_270)[quadrant]
 
-    rad = numpy.radians(angle)
-    qx = snap_nm(ox + numpy.cos(rad) * (px - ox) - numpy.sin(rad) * (py - oy))
-    qy = snap_nm(oy + numpy.sin(rad) * (px - ox) + numpy.cos(rad) * (py - oy))
 
-    return Port(qx, qy, port.orientation + angle)
+def rotation_matrix3(rotation_deg: int) -> NDArray[numpy.int32]:
+    rot2 = rotation_matrix2(rotation_deg)
+    rot3 = numpy.zeros((3, 3), dtype=numpy.int32)
+    rot3[:2, :2] = rot2
+    rot3[2, 2] = 1
+    return rot3
+
+
+def translate_port(port: Port, dx: int | float, dy: int | float) -> Port:
+    return Port(port.x + dx, port.y + dy, port.r)
+
+
+def rotate_port(port: Port, angle: int | float, origin: tuple[int | float, int | float] = (0, 0)) -> Port:
+    angle_i = _normalize_angle(angle)
+    rot = rotation_matrix2(angle_i)
+    origin_xy = numpy.array((int(round(origin[0])), int(round(origin[1]))), dtype=numpy.int32)
+    rel = numpy.array((port.x, port.y), dtype=numpy.int32) - origin_xy
+    rotated = origin_xy + rot @ rel
+    return Port(int(rotated[0]), int(rotated[1]), port.r + angle_i)

inire/router/astar.py

@@ -2,16 +2,15 @@ from __future__ import annotations
 
 import heapq
 import logging
-from typing import TYPE_CHECKING, Literal, Any
+from typing import TYPE_CHECKING, Any, Literal
 
-import numpy
 import shapely
 
-from inire.geometry.components import Bend90, SBend, Straight, snap_search_grid
+from inire.constants import TOLERANCE_LINEAR
+from inire.geometry.components import Bend90, SBend, Straight
 from inire.geometry.primitives import Port
 from inire.router.config import RouterConfig
 from inire.router.visibility import VisibilityManager
-from inire.constants import DEFAULT_SEARCH_GRID_SNAP_UM, TOLERANCE_LINEAR, TOLERANCE_ANGULAR
 
 if TYPE_CHECKING:
     from inire.geometry.components import ComponentResult
@@ -21,10 +20,7 @@ logger = logging.getLogger(__name__)
 
 
 class AStarNode:
-    """
-    A node in the A* search tree.
-    """
-    __slots__ = ('port', 'g_cost', 'h_cost', 'fh_cost', 'parent', 'component_result')
+    __slots__ = ("port", "g_cost", "h_cost", "fh_cost", "parent", "component_result")
 
     def __init__(
         self,
@@ -46,16 +42,20 @@ class AStarNode:
 
 
 class AStarMetrics:
-    """
-    Performance metrics and instrumentation for A* search.
-    """
-    __slots__ = ('total_nodes_expanded', 'last_expanded_nodes', 'nodes_expanded', 
-                 'moves_generated', 'moves_added', 'pruned_closed_set', 
-                 'pruned_hard_collision', 'pruned_cost')
+    __slots__ = (
+        "total_nodes_expanded",
+        "last_expanded_nodes",
+        "nodes_expanded",
+        "moves_generated",
+        "moves_added",
+        "pruned_closed_set",
+        "pruned_hard_collision",
+        "pruned_cost",
+    )
 
     def __init__(self) -> None:
         self.total_nodes_expanded = 0
-        self.last_expanded_nodes: list[tuple[float, float, float]] = []
+        self.last_expanded_nodes: list[tuple[int, int, int]] = []
         self.nodes_expanded = 0
         self.moves_generated = 0
         self.moves_added = 0
@@ -64,7 +64,6 @@ class AStarMetrics:
         self.pruned_cost = 0
 
     def reset_per_route(self) -> None:
-        """ Reset metrics that are specific to a single route() call. """
         self.nodes_expanded = 0
         self.moves_generated = 0
         self.moves_added = 0
@@ -73,97 +72,71 @@ class AStarMetrics:
         self.pruned_cost = 0
         self.last_expanded_nodes = []
 
-    def get_summary_dict(self) -> dict[str, int]:
-        """ Return a dictionary of current metrics. """
-        return {
-            'nodes_expanded': self.nodes_expanded,
-            'moves_generated': self.moves_generated,
-            'moves_added': self.moves_added,
-            'pruned_closed_set': self.pruned_closed_set,
-            'pruned_hard_collision': self.pruned_hard_collision,
-            'pruned_cost': self.pruned_cost
-        }
-
 
 class AStarContext:
-    """
-    Persistent state for A* search, decoupled from search logic.
-    """
-    __slots__ = ('cost_evaluator', 'config', 'visibility_manager', 
-                 'move_cache_rel', 'move_cache_abs', 'hard_collision_set', 'static_safe_cache', 'max_cache_size')
+    __slots__ = (
+        "cost_evaluator",
+        "config",
+        "visibility_manager",
+        "move_cache_rel",
+        "move_cache_abs",
+        "hard_collision_set",
+        "static_safe_cache",
+        "max_cache_size",
+    )
 
     def __init__(
         self,
         cost_evaluator: CostEvaluator,
         node_limit: int = 1000000,
-            snap_size: float = DEFAULT_SEARCH_GRID_SNAP_UM,
         max_straight_length: float = 2000.0,
         min_straight_length: float = 5.0,
         bend_radii: list[float] | None = None,
         sbend_radii: list[float] | None = None,
         sbend_offsets: list[float] | None = None,
         bend_penalty: float = 250.0,
-            sbend_penalty: float = 500.0,
+        sbend_penalty: float | None = None,
         bend_collision_type: Literal["arc", "bbox", "clipped_bbox"] | Any = "arc",
         bend_clip_margin: float = 10.0,
         max_cache_size: int = 1000000,
     ) -> None:
+        actual_sbend_penalty = 2.0 * bend_penalty if sbend_penalty is None else sbend_penalty
         self.cost_evaluator = cost_evaluator
         self.max_cache_size = max_cache_size
-        
-        # Use provided lists or defaults for the configuration
-        br = bend_radii if bend_radii is not None else [50.0, 100.0]
-        sr = sbend_radii if sbend_radii is not None else [5.0, 10.0, 50.0, 100.0]
-
         self.config = RouterConfig(
             node_limit=node_limit,
-            snap_size=snap_size,
             max_straight_length=max_straight_length,
             min_straight_length=min_straight_length,
-            bend_radii=br,
-            sbend_radii=sr,
+            bend_radii=bend_radii if bend_radii is not None else [50.0, 100.0],
+            sbend_radii=sbend_radii if sbend_radii is not None else [5.0, 10.0, 50.0, 100.0],
             sbend_offsets=sbend_offsets,
             bend_penalty=bend_penalty,
-            sbend_penalty=sbend_penalty,
+            sbend_penalty=actual_sbend_penalty,
             bend_collision_type=bend_collision_type,
-            bend_clip_margin=bend_clip_margin
+            bend_clip_margin=bend_clip_margin,
         )
         self.cost_evaluator.config = self.config
+        self.cost_evaluator._refresh_cached_config()
 
         self.visibility_manager = VisibilityManager(self.cost_evaluator.collision_engine)
-        
-        # Long-lived caches (shared across multiple route calls)
         self.move_cache_rel: dict[tuple, ComponentResult] = {}
         self.move_cache_abs: dict[tuple, ComponentResult] = {}
         self.hard_collision_set: set[tuple] = set()
         self.static_safe_cache: set[tuple] = set()
 
     def clear_static_caches(self) -> None:
-        """ Clear caches that depend on the state of static obstacles. """
         self.hard_collision_set.clear()
         self.static_safe_cache.clear()
+        self.visibility_manager.clear_cache()
 
     def check_cache_eviction(self) -> None:
-        """ 
-        Trigger FIFO eviction of Absolute moves if cache exceeds max_cache_size.
-        We preserve Relative move templates.
-        """
-        # Trigger eviction if 20% over limit to reduce frequency
-        if len(self.move_cache_abs) > self.max_cache_size * 1.2:
+        if len(self.move_cache_abs) <= self.max_cache_size * 1.2:
+            return
         num_to_evict = int(len(self.move_cache_abs) * 0.25)
-            # Efficient FIFO eviction
-            keys_to_evict = []
-            it = iter(self.move_cache_abs)
-            for _ in range(num_to_evict):
-                try: keys_to_evict.append(next(it))
-                except StopIteration: break
-            for k in keys_to_evict:
-                del self.move_cache_abs[k]
-            
-            # Decouple collision cache clearing - only clear if truly massive
-            if len(self.hard_collision_set) > 2000000:
-                 self.hard_collision_set.clear()
-                 self.static_safe_cache.clear()
+        for idx, key in enumerate(list(self.move_cache_abs.keys())):
+            if idx >= num_to_evict:
+                break
+            del self.move_cache_abs[key]
 
 
 def route_astar(
@@ -172,8 +145,8 @@ def route_astar(
     net_width: float,
     context: AStarContext,
     metrics: AStarMetrics | None = None,
-        net_id: str = 'default',
-        bend_collision_type: Literal['arc', 'bbox', 'clipped_bbox'] | None = None,
+    net_id: str = "default",
+    bend_collision_type: Literal["arc", "bbox", "clipped_bbox"] | None = None,
     return_partial: bool = False,
     store_expanded: bool = False,
     skip_congestion: bool = False,
@@ -181,48 +154,29 @@ def route_astar(
     self_collision_check: bool = False,
     node_limit: int | None = None,
 ) -> list[ComponentResult] | None:
-    """
-    Functional implementation of A* routing.
-    """
     if metrics is None:
         metrics = AStarMetrics()
-    
     metrics.reset_per_route()
 
-    # Enforce Grid Alignment for start and target
-    snap = context.config.snap_size
-    start_snapped = Port(snap_search_grid(start.x, snap), snap_search_grid(start.y, snap), start.orientation, snap=False)
-    target_snapped = Port(snap_search_grid(target.x, snap), snap_search_grid(target.y, snap), target.orientation, snap=False)
-    
-    # Per-route congestion cache (not shared across different routes)
-    congestion_cache: dict[tuple, int] = {}
-
     if bend_collision_type is not None:
         context.config.bend_collision_type = bend_collision_type
 
-    context.cost_evaluator.set_target(target_snapped)
-    
+    context.cost_evaluator.set_target(target)
     open_set: list[AStarNode] = []
-    inv_snap = 1.0 / snap
-    
-    # (x_grid, y_grid, orientation_grid) -> min_g_cost
     closed_set: dict[tuple[int, int, int], float] = {}
+    congestion_cache: dict[tuple, int] = {}
 
-    start_node = AStarNode(start_snapped, 0.0, context.cost_evaluator.h_manhattan(start_snapped, target_snapped))
+    start_node = AStarNode(start, 0.0, context.cost_evaluator.h_manhattan(start, target))
     heapq.heappush(open_set, start_node)
-
     best_node = start_node
-    nodes_expanded = 0
-    
     effective_node_limit = node_limit if node_limit is not None else context.config.node_limit
+    nodes_expanded = 0
 
     while open_set:
         if nodes_expanded >= effective_node_limit:
             return reconstruct_path(best_node) if return_partial else None
 
         current = heapq.heappop(open_set)
-        
-        # Cost Pruning (Fail Fast)
         if max_cost is not None and current.fh_cost[0] > max_cost:
             metrics.pruned_cost += 1
             continue
@@ -230,36 +184,62 @@ def route_astar(
         if current.h_cost < best_node.h_cost:
             best_node = current
 
-        state = (int(round(current.port.x * inv_snap)), int(round(current.port.y * inv_snap)), int(round(current.port.orientation)))
+        state = current.port.as_tuple()
         if state in closed_set and closed_set[state] <= current.g_cost + TOLERANCE_LINEAR:
             continue
         closed_set[state] = current.g_cost
 
         if store_expanded:
-            metrics.last_expanded_nodes.append((current.port.x, current.port.y, current.port.orientation))
+            metrics.last_expanded_nodes.append(state)
 
         nodes_expanded += 1
         metrics.total_nodes_expanded += 1
         metrics.nodes_expanded += 1
 
-        # Check if we reached the target exactly
-        if (abs(current.port.x - target_snapped.x) < TOLERANCE_LINEAR and
-                abs(current.port.y - target_snapped.y) < TOLERANCE_LINEAR and
-                abs(current.port.orientation - target_snapped.orientation) < 0.1):
+        if current.port == target:
             return reconstruct_path(current)
 
-        # Expansion
         expand_moves(
-            current, target_snapped, net_width, net_id, open_set, closed_set, 
-            context, metrics, congestion_cache,
-            snap=snap, inv_snap=inv_snap, parent_state=state, 
-            max_cost=max_cost, skip_congestion=skip_congestion,
-            self_collision_check=self_collision_check
+            current,
+            target,
+            net_width,
+            net_id,
+            open_set,
+            closed_set,
+            context,
+            metrics,
+            congestion_cache,
+            max_cost=max_cost,
+            skip_congestion=skip_congestion,
+            self_collision_check=self_collision_check,
         )
 
     return reconstruct_path(best_node) if return_partial else None
 
 
+def _quantized_lengths(values: list[float], max_reach: float) -> list[int]:
+    out = {int(round(v)) for v in values if v > 0 and v <= max_reach + 0.01}
+    return sorted((v for v in out if v > 0), reverse=True)
+
+
+def _sbend_forward_span(offset: float, radius: float) -> float | None:
+    abs_offset = abs(offset)
+    if abs_offset <= TOLERANCE_LINEAR or radius <= 0 or abs_offset >= 2.0 * radius:
+        return None
+    theta = __import__("math").acos(1.0 - abs_offset / (2.0 * radius))
+    return 2.0 * radius * __import__("math").sin(theta)
+
+
+def _previous_move_metadata(node: AStarNode) -> tuple[str | None, float | None]:
+    result = node.component_result
+    if result is None:
+        return None, None
+    move_type = result.move_type
+    if move_type == "Straight":
+        return move_type, result.length
+    return move_type, None
+
+
 def expand_moves(
     current: AStarNode,
     target: Port,
@@ -270,131 +250,163 @@ def expand_moves(
     context: AStarContext,
     metrics: AStarMetrics,
     congestion_cache: dict[tuple, int],
-        snap: float = 1.0,
-        inv_snap: float | None = None,
-        parent_state: tuple[int, int, int] | None = None,
     max_cost: float | None = None,
     skip_congestion: bool = False,
     self_collision_check: bool = False,
 ) -> None:
-    """
-    Extract moves and add valid successors to the open set.
-    """
     cp = current.port
-    if inv_snap is None: inv_snap = 1.0 / snap
-    if parent_state is None:
-         parent_state = (int(round(cp.x * inv_snap)), int(round(cp.y * inv_snap)), int(round(cp.orientation)))
-    
+    prev_move_type, prev_straight_length = _previous_move_metadata(current)
     dx_t = target.x - cp.x
     dy_t = target.y - cp.y
     dist_sq = dx_t * dx_t + dy_t * dy_t
 
-    rad = numpy.radians(cp.orientation)
-    cos_v, sin_v = numpy.cos(rad), numpy.sin(rad)
+    if cp.r == 0:
+        cos_v, sin_v = 1.0, 0.0
+    elif cp.r == 90:
+        cos_v, sin_v = 0.0, 1.0
+    elif cp.r == 180:
+        cos_v, sin_v = -1.0, 0.0
+    else:
+        cos_v, sin_v = 0.0, -1.0
 
-    # 1. DIRECT JUMP TO TARGET
     proj_t = dx_t * cos_v + dy_t * sin_v
     perp_t = -dx_t * sin_v + dy_t * cos_v
+    dx_local = proj_t
+    dy_local = perp_t
 
-    # A. Straight Jump (Only if target aligns with grid state or direct jump is enabled)
-    if proj_t > 0 and abs(perp_t) < 1e-3 and abs(cp.orientation - target.orientation) < 0.1:
-         max_reach = context.cost_evaluator.collision_engine.ray_cast(cp, cp.orientation, proj_t + 1.0)
-         if max_reach >= proj_t - 0.01:
+    if proj_t > 0 and abs(perp_t) < 1e-6 and cp.r == target.r:
+        max_reach = context.cost_evaluator.collision_engine.ray_cast(cp, cp.r, proj_t + 1.0, net_width=net_width)
+        if max_reach >= proj_t - 0.01 and (
+            prev_straight_length is None or proj_t < prev_straight_length - TOLERANCE_LINEAR
+        ):
             process_move(
-                  current, target, net_width, net_id, open_set, closed_set, context, metrics, congestion_cache,
-                  f'S{proj_t}', 'S', (proj_t,), skip_congestion, inv_snap=inv_snap, snap_to_grid=False, 
-                  parent_state=parent_state, max_cost=max_cost, snap=snap, self_collision_check=self_collision_check
+                current,
+                target,
+                net_width,
+                net_id,
+                open_set,
+                closed_set,
+                context,
+                metrics,
+                congestion_cache,
+                "S",
+                (int(round(proj_t)),),
+                skip_congestion,
+                max_cost=max_cost,
+                self_collision_check=self_collision_check,
             )
 
-    # 2. VISIBILITY JUMPS & MAX REACH
-    max_reach = context.cost_evaluator.collision_engine.ray_cast(cp, cp.orientation, context.config.max_straight_length)
+    max_reach = context.cost_evaluator.collision_engine.ray_cast(cp, cp.r, context.config.max_straight_length, net_width=net_width)
+    candidate_lengths = [
+        context.config.min_straight_length,
+        max_reach,
+        max_reach / 2.0,
+        max_reach - 5.0,
+    ]
 
-    straight_lengths = set()
-    if max_reach > context.config.min_straight_length:
-         straight_lengths.add(snap_search_grid(max_reach, snap))
+    axis_target_dist = abs(dx_t) if cp.r in (0, 180) else abs(dy_t)
+    candidate_lengths.append(axis_target_dist)
     for radius in context.config.bend_radii:
-              if max_reach > radius + context.config.min_straight_length:
-                   straight_lengths.add(snap_search_grid(max_reach - radius, snap))
+        candidate_lengths.extend((max_reach - radius, axis_target_dist - radius, axis_target_dist - 2.0 * radius))
 
-         if max_reach > context.config.min_straight_length + 5.0:
-              straight_lengths.add(snap_search_grid(max_reach - 5.0, snap))
+    if cp.r == target.r and dx_local > 0 and abs(dy_local) > TOLERANCE_LINEAR:
+        for radius in context.config.sbend_radii:
+            sbend_span = _sbend_forward_span(dy_local, radius)
+            if sbend_span is None:
+                continue
+            candidate_lengths.extend((dx_local - sbend_span, dx_local - 2.0 * sbend_span))
 
-    straight_lengths.add(context.config.min_straight_length)
-    if max_reach > context.config.min_straight_length * 4:
-         straight_lengths.add(snap_search_grid(max_reach / 2.0, snap))
-
-    if abs(cp.orientation % 180) < 0.1: # Horizontal
-         target_dist = abs(target.x - cp.x)
-         if target_dist <= max_reach and target_dist > context.config.min_straight_length:
-              sl = snap_search_grid(target_dist, snap)
-              if sl > 0.1: straight_lengths.add(sl)
-         for radius in context.config.bend_radii:
-              for l in [target_dist - radius, target_dist - 2*radius]:
-                   if l > context.config.min_straight_length:
-                        s_l = snap_search_grid(l, snap)
-                        if s_l <= max_reach and s_l > 0.1: straight_lengths.add(s_l)
-    else: # Vertical
-         target_dist = abs(target.y - cp.y)
-         if target_dist <= max_reach and target_dist > context.config.min_straight_length:
-              sl = snap_search_grid(target_dist, snap)
-              if sl > 0.1: straight_lengths.add(sl)
-         for radius in context.config.bend_radii:
-              for l in [target_dist - radius, target_dist - 2*radius]:
-                   if l > context.config.min_straight_length:
-                        s_l = snap_search_grid(l, snap)
-                        if s_l <= max_reach and s_l > 0.1: straight_lengths.add(s_l)
-
-    for length in sorted(straight_lengths, reverse=True):
-        process_move(
-            current, target, net_width, net_id, open_set, closed_set, context, metrics, congestion_cache,
-            f'S{length}', 'S', (length,), skip_congestion, inv_snap=inv_snap, parent_state=parent_state, 
-            max_cost=max_cost, snap=snap, self_collision_check=self_collision_check
-        )
-
-    # 3. BENDS & SBENDS
-    angle_to_target = numpy.degrees(numpy.arctan2(target.y - cp.y, target.x - cp.x))
-    allow_backwards = (dist_sq < 150*150)
-
-    for radius in context.config.bend_radii:
-        for direction in ['CW', 'CCW']:
-            if not allow_backwards:
-                turn = 90 if direction == 'CCW' else -90
-                new_ori = (cp.orientation + turn) % 360
-                new_diff = (angle_to_target - new_ori + 180) % 360 - 180
-                if abs(new_diff) > 135:
+    for length in _quantized_lengths(candidate_lengths, max_reach):
+        if length < context.config.min_straight_length:
+            continue
+        if prev_straight_length is not None and length >= prev_straight_length - TOLERANCE_LINEAR:
             continue
         process_move(
-                current, target, net_width, net_id, open_set, closed_set, context, metrics, congestion_cache,
-                f'B{radius}{direction}', 'B', (radius, direction), skip_congestion, inv_snap=inv_snap, 
-                parent_state=parent_state, max_cost=max_cost, snap=snap, self_collision_check=self_collision_check
+            current,
+            target,
+            net_width,
+            net_id,
+            open_set,
+            closed_set,
+            context,
+            metrics,
+            congestion_cache,
+            "S",
+            (length,),
+            skip_congestion,
+            max_cost=max_cost,
+            self_collision_check=self_collision_check,
         )
 
-    # 4. SBENDS
-    max_sbend_r = max(context.config.sbend_radii) if context.config.sbend_radii else 0
-    if max_sbend_r > 0:
-        user_offsets = context.config.sbend_offsets
-        offsets: set[float] = set(user_offsets) if user_offsets is not None else set()
-        dx_local = (target.x - cp.x) * cos_v + (target.y - cp.y) * sin_v
-        dy_local = -(target.x - cp.x) * sin_v + (target.y - cp.y) * cos_v
+    angle_to_target = 0.0
+    if dx_t != 0 or dy_t != 0:
+        angle_to_target = float((round((180.0 / 3.141592653589793) * __import__("math").atan2(dy_t, dx_t)) + 360.0) % 360.0)
+    allow_backwards = dist_sq < 150 * 150
 
-        if dx_local > 0 and abs(dy_local) < 2 * max_sbend_r:
-             min_d = numpy.sqrt(max(0, 4 * (abs(dy_local)/2.0) * abs(dy_local) - dy_local**2))
-             if dx_local >= min_d: offsets.add(dy_local)
+    for radius in context.config.bend_radii:
+        for direction in ("CW", "CCW"):
+            if not allow_backwards:
+                turn = 90 if direction == "CCW" else -90
+                new_ori = (cp.r + turn) % 360
+                new_diff = (angle_to_target - new_ori + 180.0) % 360.0 - 180.0
+                if abs(new_diff) > 135.0:
+                    continue
+            process_move(
+                current,
+                target,
+                net_width,
+                net_id,
+                open_set,
+                closed_set,
+                context,
+                metrics,
+                congestion_cache,
+                "B",
+                (radius, direction),
+                skip_congestion,
+                max_cost=max_cost,
+                self_collision_check=self_collision_check,
+            )
 
-        if user_offsets is None:
-             for sign in [-1, 1]:
-                  # Adaptive sampling: scale steps by snap_size but ensure enough range
-                  for i in [1, 2, 5, 13, 34, 89]:
-                       o = sign * i * snap
-                       if abs(o) < 2 * max_sbend_r: offsets.add(o)
+    max_sbend_r = max(context.config.sbend_radii) if context.config.sbend_radii else 0.0
+    if max_sbend_r <= 0 or prev_move_type == "SBend":
+        return
+
+    explicit_offsets = context.config.sbend_offsets
+    offsets: set[int] = set(int(round(v)) for v in explicit_offsets or [])
+
+    # S-bends preserve orientation, so the implicit search only makes sense
+    # when the target is ahead in local coordinates and keeps the same
+    # orientation. Generating generic speculative offsets on the integer lattice
+    # explodes the search space without contributing useful moves.
+    if target.r == cp.r and 0 < dx_local <= 4 * max_sbend_r:
+        if 0 < abs(dy_local) < 2 * max_sbend_r:
+            offsets.add(int(round(dy_local)))
+
+    if not offsets:
+        return
 
     for offset in sorted(offsets):
+        if offset == 0:
+            continue
         for radius in context.config.sbend_radii:
-                if abs(offset) >= 2 * radius: continue
+            if abs(offset) >= 2 * radius:
+                continue
             process_move(
-                    current, target, net_width, net_id, open_set, closed_set, context, metrics, congestion_cache,
-                    f'SB{offset}R{radius}', 'SB', (offset, radius), skip_congestion, inv_snap=inv_snap, 
-                    parent_state=parent_state, max_cost=max_cost, snap=snap, self_collision_check=self_collision_check
+                current,
+                target,
+                net_width,
+                net_id,
+                open_set,
+                closed_set,
+                context,
+                metrics,
+                congestion_cache,
+                "SB",
+                (offset, radius),
+                skip_congestion,
+                max_cost=max_cost,
+                self_collision_check=self_collision_check,
             )
 
 
@@ -408,87 +420,90 @@ def process_move(
     context: AStarContext,
     metrics: AStarMetrics,
     congestion_cache: dict[tuple, int],
-        move_type: str,
-        move_class: Literal['S', 'B', 'SB'],
+    move_class: Literal["S", "B", "SB"],
     params: tuple,
     skip_congestion: bool,
-        inv_snap: float | None = None,
-        snap_to_grid: bool = True,
-        parent_state: tuple[int, int, int] | None = None,
     max_cost: float | None = None,
-        snap: float = 1.0,
     self_collision_check: bool = False,
 ) -> None:
-    """
-    Generate or retrieve geometry and delegate to add_node.
-    """
     cp = parent.port
-    if inv_snap is None: inv_snap = 1.0 / snap
-    base_ori = float(int(cp.orientation + 0.5))
-    if parent_state is None:
-         gx = int(round(cp.x * inv_snap))
-         gy = int(round(cp.y * inv_snap))
-         go = int(round(cp.orientation))
-         parent_state = (gx, gy, go)
-    else:
-         gx, gy, go = parent_state
-    
     coll_type = context.config.bend_collision_type
     coll_key = id(coll_type) if isinstance(coll_type, shapely.geometry.Polygon) else coll_type
+    self_dilation = context.cost_evaluator.collision_engine.clearance / 2.0
 
-    abs_key = (parent_state, move_class, params, net_width, coll_key, snap_to_grid)
+    abs_key = (
+        cp.as_tuple(),
+        move_class,
+        params,
+        net_width,
+        coll_key,
+        context.config.bend_clip_margin,
+        self_dilation,
+    )
     if abs_key in context.move_cache_abs:
         res = context.move_cache_abs[abs_key]
-        move_radius = params[0] if move_class == 'B' else (params[1] if move_class == 'SB' else None)
-        add_node(
-            parent, res, target, net_width, net_id, open_set, closed_set, context, metrics, congestion_cache,
-            move_type, move_radius=move_radius, snap=snap, skip_congestion=skip_congestion, 
-            inv_snap=inv_snap, parent_state=parent_state, max_cost=max_cost, 
-            self_collision_check=self_collision_check
-        )
-        return
-
-    # Trigger periodic cache eviction check (only on Absolute cache misses)
+    else:
         context.check_cache_eviction()
-
-    # Template Cache Key (Relative to Port 0,0,Ori)
-    # We snap the parameters to ensure template re-use
-    snapped_params = params
-    if move_class == 'SB':
-         snapped_params = (snap_search_grid(params[0], snap), params[1])
-    
-    self_dilation = context.cost_evaluator.collision_engine.clearance / 2.0
-    rel_key = (base_ori, move_class, snapped_params, net_width, coll_key, self_dilation, snap_to_grid)
-    
-    cache_key = (gx, gy, go, move_type, net_width)
-    if cache_key in context.hard_collision_set:
-        return
-        
+        base_port = Port(0, 0, cp.r)
+        rel_key = (
+            cp.r,
+            move_class,
+            params,
+            net_width,
+            coll_key,
+            context.config.bend_clip_margin,
+            self_dilation,
+        )
         if rel_key in context.move_cache_rel:
             res_rel = context.move_cache_rel[rel_key]
         else:
             try:
-            p0 = Port(0, 0, base_ori)
-            if move_class == 'S':
-                res_rel = Straight.generate(p0, params[0], net_width, dilation=self_dilation, snap_to_grid=snap_to_grid, snap_size=snap)
-            elif move_class == 'B':
-                res_rel = Bend90.generate(p0, params[0], net_width, params[1], collision_type=context.config.bend_collision_type, clip_margin=context.config.bend_clip_margin, dilation=self_dilation, snap_to_grid=snap_to_grid, snap_size=snap)
-            elif move_class == 'SB':
-                res_rel = SBend.generate(p0, snapped_params[0], snapped_params[1], net_width, collision_type=context.config.bend_collision_type, clip_margin=context.config.bend_clip_margin, dilation=self_dilation, snap_to_grid=snap_to_grid, snap_size=snap)
+                if move_class == "S":
+                    res_rel = Straight.generate(base_port, params[0], net_width, dilation=self_dilation)
+                elif move_class == "B":
+                    res_rel = Bend90.generate(
+                        base_port,
+                        params[0],
+                        net_width,
+                        params[1],
+                        collision_type=context.config.bend_collision_type,
+                        clip_margin=context.config.bend_clip_margin,
+                        dilation=self_dilation,
+                    )
                 else:
+                    res_rel = SBend.generate(
+                        base_port,
+                        params[0],
+                        params[1],
+                        net_width,
+                        collision_type=context.config.bend_collision_type,
+                        clip_margin=context.config.bend_clip_margin,
+                        dilation=self_dilation,
+                    )
+            except ValueError:
                 return
             context.move_cache_rel[rel_key] = res_rel
-        except (ValueError, ZeroDivisionError):
-            return
-
-    res = res_rel.translate(cp.x, cp.y, rel_gx=res_rel.rel_gx + gx, rel_gy=res_rel.rel_gy + gy, rel_go=res_rel.rel_go)
+        res = res_rel.translate(cp.x, cp.y)
         context.move_cache_abs[abs_key] = res
-    move_radius = params[0] if move_class == 'B' else (params[1] if move_class == 'SB' else None)
+
+    move_radius = params[0] if move_class == "B" else (params[1] if move_class == "SB" else None)
     add_node(
-        parent, res, target, net_width, net_id, open_set, closed_set, context, metrics, congestion_cache,
-        move_type, move_radius=move_radius, snap=snap, skip_congestion=skip_congestion, 
-        inv_snap=inv_snap, parent_state=parent_state, max_cost=max_cost, 
-        self_collision_check=self_collision_check
+        parent,
+        res,
+        target,
+        net_width,
+        net_id,
+        open_set,
+        closed_set,
+        context,
+        metrics,
+        congestion_cache,
+        move_class,
+        abs_key,
+        move_radius=move_radius,
+        skip_congestion=skip_congestion,
+        max_cost=max_cost,
+        self_collision_check=self_collision_check,
     )
 
 
@@ -504,22 +519,14 @@ def add_node(
     metrics: AStarMetrics,
     congestion_cache: dict[tuple, int],
     move_type: str,
+    cache_key: tuple,
     move_radius: float | None = None,
-        snap: float = 1.0,
     skip_congestion: bool = False,
-        inv_snap: float | None = None,
-        parent_state: tuple[int, int, int] | None = None,
     max_cost: float | None = None,
     self_collision_check: bool = False,
 ) -> None:
-    """
-    Check collisions and costs, and add node to the open set.
-    """
     metrics.moves_generated += 1
-    state = (result.rel_gx, result.rel_gy, result.rel_go)
-    
-    # Early pruning using lower-bound total cost
-    # child.total_g >= parent.total_g + move_length
+    state = result.end_port.as_tuple()
     new_lower_bound_g = parent.g_cost + result.length
     if state in closed_set and closed_set[state] <= new_lower_bound_g + TOLERANCE_LINEAR:
         metrics.pruned_closed_set += 1
@@ -527,30 +534,22 @@ def add_node(
 
     parent_p = parent.port
     end_p = result.end_port
-    if parent_state is None:
-         pgx, pgy, pgo = int(round(parent_p.x * inv_snap)), int(round(parent_p.y * inv_snap)), int(round(parent_p.orientation))
-    else:
-         pgx, pgy, pgo = parent_state
-    cache_key = (pgx, pgy, pgo, move_type, net_width)
 
     if cache_key in context.hard_collision_set:
         metrics.pruned_hard_collision += 1
         return
 
-    is_static_safe = (cache_key in context.static_safe_cache)
+    is_static_safe = cache_key in context.static_safe_cache
     if not is_static_safe:
         ce = context.cost_evaluator.collision_engine
-        collision_found = False
-        if 'S' in move_type and 'SB' not in move_type:
-             collision_found = ce.check_move_straight_static(parent_p, result.length)
+        if move_type == "S":
+            collision_found = ce.check_move_straight_static(parent_p, result.length, net_width=net_width)
         else:
-             collision_found = ce.check_move_static(result, start_port=parent_p, end_port=end_p)
-        
+            collision_found = ce.check_move_static(result, start_port=parent_p, end_port=end_p, net_width=net_width)
         if collision_found:
             context.hard_collision_set.add(cache_key)
             metrics.pruned_hard_collision += 1
             return
-        else:
         context.static_safe_cache.add(cache_key)
 
     total_overlaps = 0
@@ -561,7 +560,6 @@ def add_node(
             total_overlaps = context.cost_evaluator.collision_engine.check_move_congestion(result, net_id)
             congestion_cache[cache_key] = total_overlaps
 
-    # SELF-COLLISION CHECK (Optional for performance)
     if self_collision_check:
         curr_p = parent
         new_tb = result.total_bounds
@@ -569,8 +567,7 @@ def add_node(
             ancestor_res = curr_p.component_result
             if ancestor_res:
                 anc_tb = ancestor_res.total_bounds
-                  if (new_tb[0] < anc_tb[2] and new_tb[2] > anc_tb[0] and
-                      new_tb[1] < anc_tb[3] and new_tb[3] > anc_tb[1]):
+                if new_tb[0] < anc_tb[2] and new_tb[2] > anc_tb[0] and new_tb[1] < anc_tb[3] and new_tb[3] > anc_tb[1]:
                     for p_anc in ancestor_res.geometry:
                         for p_new in result.geometry:
                             if p_new.intersects(p_anc) and not p_new.touches(p_anc):
@@ -578,18 +575,30 @@ def add_node(
             curr_p = curr_p.parent
 
     penalty = 0.0
-    if 'SB' in move_type: penalty = context.config.sbend_penalty
-    elif 'B' in move_type: penalty = context.config.bend_penalty
-    if move_radius is not None and move_radius > TOLERANCE_LINEAR: penalty *= (10.0 / move_radius)**0.5
+    if move_type == "SB":
+        penalty = context.config.sbend_penalty
+    elif move_type == "B":
+        penalty = context.config.bend_penalty
+    if move_radius is not None and move_radius > TOLERANCE_LINEAR:
+        penalty *= (10.0 / move_radius) ** 0.5
 
     move_cost = context.cost_evaluator.evaluate_move(
-        None, result.end_port, net_width, net_id,
-        start_port=parent_p, length=result.length,
-        dilated_geometry=None, penalty=penalty,
-        skip_static=True, skip_congestion=True # Congestion overlaps already calculated
+        result.geometry,
+        result.end_port,
+        net_width,
+        net_id,
+        start_port=parent_p,
+        length=result.length,
+        dilated_geometry=result.dilated_geometry,
+        penalty=penalty,
+        skip_static=True,
+        skip_congestion=True,
     )
     move_cost += total_overlaps * context.cost_evaluator.congestion_penalty
 
+    if max_cost is not None and parent.g_cost + move_cost > max_cost:
+        metrics.pruned_cost += 1
+        return
     if move_cost > 1e12:
         metrics.pruned_cost += 1
         return
@@ -605,7 +614,6 @@ def add_node(
 
 
 def reconstruct_path(end_node: AStarNode) -> list[ComponentResult]:
-    """ Trace back from end node to start node to get the path. """
     path = []
     curr: AStarNode | None = end_node
     while curr and curr.component_result:

inire/router/config.py

@@ -10,7 +10,6 @@ class RouterConfig:
     """Configuration parameters for the A* Router."""
 
     node_limit: int = 1000000
-    snap_size: float = 5.0
     # Sparse Sampling Configuration
     max_straight_length: float = 2000.0
     num_straight_samples: int = 5

inire/router/cost.py

@@ -3,8 +3,9 @@ from __future__ import annotations
 from typing import TYPE_CHECKING, Any
 
 import numpy as np
-from inire.router.config import CostConfig
+
 from inire.constants import TOLERANCE_LINEAR
+from inire.router.config import CostConfig
 
 if TYPE_CHECKING:
     from shapely.geometry import Polygon
@@ -15,25 +16,20 @@ if TYPE_CHECKING:
 
 
 class CostEvaluator:
-    """
-    Calculates total path and proximity costs.
-    """
-    __slots__ = ('collision_engine', 'danger_map', 'config', 'unit_length_cost', 'greedy_h_weight', 'congestion_penalty',
-                 '_target_x', '_target_y', '_target_ori', '_target_cos', '_target_sin', '_min_radius')
-
-    collision_engine: CollisionEngine
-    """ The engine for intersection checks """
-
-    danger_map: DangerMap
-    """ Pre-computed grid for heuristic proximity costs """
-
-    config: Any
-    """ Parameter configuration (CostConfig or RouterConfig) """
-
-    unit_length_cost: float
-    greedy_h_weight: float
-    congestion_penalty: float
-    """ Cached weight values for performance """
+    __slots__ = (
+        "collision_engine",
+        "danger_map",
+        "config",
+        "unit_length_cost",
+        "greedy_h_weight",
+        "congestion_penalty",
+        "_target_x",
+        "_target_y",
+        "_target_r",
+        "_target_cos",
+        "_target_sin",
+        "_min_radius",
+    )
 
     def __init__(
         self,
@@ -43,22 +39,10 @@ class CostEvaluator:
         greedy_h_weight: float = 1.5,
         congestion_penalty: float = 10000.0,
         bend_penalty: float = 250.0,
-            sbend_penalty: float = 500.0,
+        sbend_penalty: float | None = None,
         min_bend_radius: float = 50.0,
     ) -> None:
-        """
-        Initialize the Cost Evaluator.
-
-        Args:
-            collision_engine: The engine for intersection checks.
-            danger_map: Pre-computed grid for heuristic proximity costs.
-            unit_length_cost: Cost multiplier per micrometer of path length.
-            greedy_h_weight: Heuristic weighting (A* greedy factor).
-            congestion_penalty: Multiplier for path overlaps in negotiated congestion.
-            bend_penalty: Base cost for 90-degree bends.
-            sbend_penalty: Base cost for parametric S-bends.
-            min_bend_radius: Minimum radius for 90-degree bends (used for alignment heuristic).
-        """
+        actual_sbend_penalty = 2.0 * bend_penalty if sbend_penalty is None else sbend_penalty
         self.collision_engine = collision_engine
         self.danger_map = danger_map
         self.config = CostConfig(
@@ -66,123 +50,86 @@ class CostEvaluator:
             greedy_h_weight=greedy_h_weight,
             congestion_penalty=congestion_penalty,
             bend_penalty=bend_penalty,
-            sbend_penalty=sbend_penalty,
+            sbend_penalty=actual_sbend_penalty,
             min_bend_radius=min_bend_radius,
         )
-
-        # Use config values
         self.unit_length_cost = self.config.unit_length_cost
         self.greedy_h_weight = self.config.greedy_h_weight
         self.congestion_penalty = self.config.congestion_penalty
-        
-        # Pre-cache configuration flags for fast path
         self._refresh_cached_config()
-
-        # Target cache
         self._target_x = 0.0
         self._target_y = 0.0
-        self._target_ori = 0.0
+        self._target_r = 0
         self._target_cos = 1.0
         self._target_sin = 0.0
 
     def _refresh_cached_config(self) -> None:
-        """ Sync internal caches with the current self.config object. """
-        if hasattr(self.config, 'min_bend_radius'):
+        if hasattr(self.config, "min_bend_radius"):
             self._min_radius = self.config.min_bend_radius
-        elif hasattr(self.config, 'bend_radii') and self.config.bend_radii:
+        elif hasattr(self.config, "bend_radii") and self.config.bend_radii:
             self._min_radius = min(self.config.bend_radii)
         else:
             self._min_radius = 50.0
-        
-        if hasattr(self.config, 'unit_length_cost'):
+        if hasattr(self.config, "unit_length_cost"):
             self.unit_length_cost = self.config.unit_length_cost
-        if hasattr(self.config, 'greedy_h_weight'):
+        if hasattr(self.config, "greedy_h_weight"):
             self.greedy_h_weight = self.config.greedy_h_weight
-        if hasattr(self.config, 'congestion_penalty'):
+        if hasattr(self.config, "congestion_penalty"):
             self.congestion_penalty = self.config.congestion_penalty
 
     def set_target(self, target: Port) -> None:
-        """ Pre-calculate target-dependent values for faster heuristic. """
         self._target_x = target.x
         self._target_y = target.y
-        self._target_ori = target.orientation
-        rad = np.radians(target.orientation)
+        self._target_r = target.r
+        rad = np.radians(target.r)
         self._target_cos = np.cos(rad)
         self._target_sin = np.sin(rad)
 
     def g_proximity(self, x: float, y: float) -> float:
-        """
-        Get proximity cost from the Danger Map.
-
-        Args:
-            x, y: Coordinate to check.
-
-        Returns:
-            Proximity cost at location.
-        """
         if self.danger_map is None:
             return 0.0
         return self.danger_map.get_cost(x, y)
 
     def h_manhattan(self, current: Port, target: Port) -> float:
-        """
-        Heuristic: weighted Manhattan distance + mandatory turn penalties.
-        """
         tx, ty = target.x, target.y
-        
-        # Avoid repeated trig for target orientation
-        if (abs(tx - self._target_x) > TOLERANCE_LINEAR or 
-            abs(ty - self._target_y) > TOLERANCE_LINEAR or
-            abs(target.orientation - self._target_ori) > 0.1):
+        if abs(tx - self._target_x) > TOLERANCE_LINEAR or abs(ty - self._target_y) > TOLERANCE_LINEAR or target.r != self._target_r:
             self.set_target(target)
 
         dx = abs(current.x - tx)
         dy = abs(current.y - ty)
         dist = dx + dy
-
         bp = self.config.bend_penalty
         penalty = 0.0
 
-        # 1. Orientation Difference
-        curr_ori = current.orientation
-        diff = abs(curr_ori - self._target_ori) % 360
-        if diff > 0.1:
-            if abs(diff - 180) < 0.1:
-                penalty += 2 * bp
-            else: # 90 or 270 degree rotation
-                penalty += 1 * bp
+        curr_r = current.r
+        diff = abs(curr_r - self._target_r) % 360
+        if diff > 0:
+            penalty += 2 * bp if diff == 180 else bp
 
-        # 2. Side Check (Entry half-plane)
         v_dx = tx - current.x
         v_dy = ty - current.y
         side_proj = v_dx * self._target_cos + v_dy * self._target_sin
         perp_dist = abs(v_dx * self._target_sin - v_dy * self._target_cos)
-        
-        if side_proj < -0.1 or (side_proj < self._min_radius and perp_dist > 0.1):
+        if side_proj < 0 or (side_proj < self._min_radius and perp_dist > 0):
             penalty += 2 * bp
 
-        # 3. Traveling Away
-        # Optimization: avoid np.radians/cos/sin if current_ori is standard 0,90,180,270
-        if curr_ori == 0: c_cos, c_sin = 1.0, 0.0
-        elif curr_ori == 90: c_cos, c_sin = 0.0, 1.0
-        elif curr_ori == 180: c_cos, c_sin = -1.0, 0.0
-        elif curr_ori == 270: c_cos, c_sin = 0.0, -1.0
+        if curr_r == 0:
+            c_cos, c_sin = 1.0, 0.0
+        elif curr_r == 90:
+            c_cos, c_sin = 0.0, 1.0
+        elif curr_r == 180:
+            c_cos, c_sin = -1.0, 0.0
         else:
-            curr_rad = np.radians(curr_ori)
-            c_cos, c_sin = np.cos(curr_rad), np.sin(curr_rad)
+            c_cos, c_sin = 0.0, -1.0
 
         move_proj = v_dx * c_cos + v_dy * c_sin
-        if move_proj < -0.1:
+        if move_proj < 0:
             penalty += 2 * bp
-
-        # 4. Jog Alignment
-        if diff < 0.1:
-            if perp_dist > 0.1:
+        if diff == 0 and perp_dist > 0:
             penalty += 2 * bp
 
         return self.greedy_h_weight * (dist + penalty)
 
-
     def evaluate_move(
         self,
         geometry: list[Polygon] | None,
@@ -196,59 +143,40 @@ class CostEvaluator:
         skip_congestion: bool = False,
         penalty: float = 0.0,
     ) -> float:
-        """
-        Calculate the cost of a single move (Straight, Bend, SBend).
-
-        Args:
-            geometry: List of polygons in the move.
-            end_port: Port at the end of the move.
-            net_width: Width of the waveguide (unused).
-            net_id: Identifier for the net.
-            start_port: Port at the start of the move.
-            length: Physical path length of the move.
-            dilated_geometry: Pre-calculated dilated polygons.
-            skip_static: If True, bypass static collision checks.
-            skip_congestion: If True, bypass congestion checks.
-            penalty: Fixed cost penalty for the move type.
-
-        Returns:
-            Total cost of the move, or 1e15 if invalid.
-        """
-        _ = net_width  # Unused
-        
-        # 1. Boundary Check
+        _ = net_width
         danger_map = self.danger_map
-        if danger_map is not None:
-            if not danger_map.is_within_bounds(end_port.x, end_port.y):
+        if danger_map is not None and not danger_map.is_within_bounds(end_port.x, end_port.y):
             return 1e15
 
         total_cost = length * self.unit_length_cost + penalty
-
-        # 2. Collision Check
         if not skip_static or not skip_congestion:
-            collision_engine = self.collision_engine
-            # Ensure geometry is provided if collision checks are enabled
             if geometry is None:
                 return 1e15
+            collision_engine = self.collision_engine
             for i, poly in enumerate(geometry):
                 dil_poly = dilated_geometry[i] if dilated_geometry else None
-                # Hard Collision (Static obstacles)
-                if not skip_static:
-                    if collision_engine.check_collision(
-                        poly, net_id, buffer_mode='static', start_port=start_port, end_port=end_port,
-                        dilated_geometry=dil_poly
+                if not skip_static and collision_engine.check_collision(
+                    poly,
+                    net_id,
+                    buffer_mode="static",
+                    start_port=start_port,
+                    end_port=end_port,
+                    dilated_geometry=dil_poly,
                 ):
                     return 1e15
-
-                # Soft Collision (Negotiated Congestion)
                 if not skip_congestion:
-                    overlaps = collision_engine.check_collision(
-                        poly, net_id, buffer_mode='congestion', dilated_geometry=dil_poly
-                    )
+                    overlaps = collision_engine.check_collision(poly, net_id, buffer_mode="congestion", dilated_geometry=dil_poly)
                     if isinstance(overlaps, int) and overlaps > 0:
                         total_cost += overlaps * self.congestion_penalty
 
-        # 3. Proximity cost from Danger Map
         if danger_map is not None:
-            total_cost += danger_map.get_cost(end_port.x, end_port.y)
+            cost_s = danger_map.get_cost(start_port.x, start_port.y) if start_port else 0.0
+            cost_e = danger_map.get_cost(end_port.x, end_port.y)
+            if start_port:
+                mid_x = (start_port.x + end_port.x) / 2.0
+                mid_y = (start_port.y + end_port.y) / 2.0
+                cost_m = danger_map.get_cost(mid_x, mid_y)
+                total_cost += length * (cost_s + cost_m + cost_e) / 3.0
+            else:
+                total_cost += length * cost_e
         return total_cost

inire/router/danger_map.py

@@ -3,6 +3,8 @@ from __future__ import annotations
 from typing import TYPE_CHECKING
 import numpy
 import shapely
+from scipy.spatial import cKDTree
+from functools import lru_cache
 
 if TYPE_CHECKING:
     from shapely.geometry import Polygon
@@ -10,36 +12,15 @@ if TYPE_CHECKING:
 
 class DangerMap:
     """
-    A pre-computed grid for heuristic proximity costs, vectorized for performance.
+    A proximity cost evaluator using a KD-Tree of obstacle boundary points.
+    Scales with obstacle perimeter rather than design area.
     """
-    __slots__ = ('minx', 'miny', 'maxx', 'maxy', 'resolution', 'safety_threshold', 'k', 'width_cells', 'height_cells', 'grid')
-
-    minx: float
-    miny: float
-    maxx: float
-    maxy: float
-    """ Boundary coordinates of the map """
-
-    resolution: float
-    """ Grid cell size in micrometers """
-
-    safety_threshold: float
-    """ Distance below which proximity costs are applied """
-
-    k: float
-    """ Cost multiplier constant """
-
-    width_cells: int
-    height_cells: int
-    """ Grid dimensions in cells """
-
-    grid: numpy.ndarray
-    """ 2D array of pre-computed costs """
+    __slots__ = ('minx', 'miny', 'maxx', 'maxy', 'resolution', 'safety_threshold', 'k', 'tree')
 
     def __init__(
             self,
             bounds: tuple[float, float, float, float],
-            resolution: float = 1.0,
+            resolution: float = 5.0,
             safety_threshold: float = 10.0,
             k: float = 1.0,
             ) -> None:
@@ -48,7 +29,7 @@ class DangerMap:
 
         Args:
             bounds: (minx, miny, maxx, maxy) in um.
-            resolution: Cell size (um).
+            resolution: Sampling resolution for obstacle boundaries (um).
             safety_threshold: Proximity limit (um).
             k: Penalty multiplier.
         """
@@ -56,79 +37,62 @@ class DangerMap:
         self.resolution = resolution
         self.safety_threshold = safety_threshold
         self.k = k
-
-        # Grid dimensions
-        self.width_cells = int(numpy.ceil((self.maxx - self.minx) / self.resolution))
-        self.height_cells = int(numpy.ceil((self.maxy - self.miny) / self.resolution))
-
-        self.grid = numpy.zeros((self.width_cells, self.height_cells), dtype=numpy.float32)
+        self.tree: cKDTree | None = None
 
     def precompute(self, obstacles: list[Polygon]) -> None:
         """
-        Pre-compute the proximity costs for the entire grid using vectorized operations.
-
-        Args:
-            obstacles: List of static obstacle geometries.
+        Pre-compute the proximity tree by sampling obstacle boundaries.
         """
-        from scipy.ndimage import distance_transform_edt
-
-        # 1. Create a binary mask of obstacles
-        mask = numpy.ones((self.width_cells, self.height_cells), dtype=bool)
-
-        # Create coordinate grids
-        x_coords = numpy.linspace(self.minx + self.resolution/2, self.maxx - self.resolution/2, self.width_cells)
-        y_coords = numpy.linspace(self.miny + self.resolution/2, self.maxy - self.resolution/2, self.height_cells)
-        xv, yv = numpy.meshgrid(x_coords, y_coords, indexing='ij')
-
+        all_points = []
         for poly in obstacles:
-            # Use shapely.contains_xy for fast vectorized point-in-polygon check
-            in_poly = shapely.contains_xy(poly, xv, yv)
-            mask[in_poly] = False
+            # Sample exterior
+            exterior = poly.exterior
+            dist = 0
+            while dist < exterior.length:
+                pt = exterior.interpolate(dist)
+                all_points.append((pt.x, pt.y))
+                dist += self.resolution
+            # Sample interiors (holes)
+            for interior in poly.interiors:
+                dist = 0
+                while dist < interior.length:
+                    pt = interior.interpolate(dist)
+                    all_points.append((pt.x, pt.y))
+                    dist += self.resolution
 
-        # 2. Distance transform (mask=True for empty space)
-        distances = distance_transform_edt(mask) * self.resolution
+        if all_points:
+            self.tree = cKDTree(numpy.array(all_points))
+        else:
+            self.tree = None
         
-        # 3. Proximity cost: k / d^2 if d < threshold, else 0
-        # Cap distances at a small epsilon (e.g. 0.1um) to avoid division by zero
-        safe_distances = numpy.maximum(distances, 0.1)
-        self.grid = numpy.where(
-            distances < self.safety_threshold,
-            self.k / (safe_distances**2),
-            0.0
-        ).astype(numpy.float32)
+        # Clear cache when tree changes
+        self._get_cost_quantized.cache_clear()
 
     def is_within_bounds(self, x: float, y: float) -> bool:
         """
         Check if a coordinate is within the design bounds.
-
-        Args:
-            x, y: Coordinate to check.
-
-        Returns:
-            True if within [min, max] for both axes.
         """
         return self.minx <= x <= self.maxx and self.miny <= y <= self.maxy
 
     def get_cost(self, x: float, y: float) -> float:
         """
-        Get the proximity cost at a specific coordinate.
-
-        Args:
-            x, y: Coordinate to look up.
-
-        Returns:
-            Pre-computed cost, or 1e15 if out of bounds.
+        Get the proximity cost at a specific coordinate using the KD-Tree.
+        Coordinates are quantized to 1nm to improve cache performance.
         """
-        # Clamp to grid range to handle upper boundary exactly
-        ix = int((x - self.minx) / self.resolution)
-        iy = int((y - self.miny) / self.resolution)
+        qx_milli = int(round(x * 1000))
+        qy_milli = int(round(y * 1000))
+        return self._get_cost_quantized(qx_milli, qy_milli)
 
-        # Handle exact upper boundary
-        if ix == self.width_cells and abs(x - self.maxx) < 1e-9:
-            ix = self.width_cells - 1
-        if iy == self.height_cells and abs(y - self.maxy) < 1e-9:
-            iy = self.height_cells - 1
-
-        if 0 <= ix < self.width_cells and 0 <= iy < self.height_cells:
-            return float(self.grid[ix, iy])
-        return 1e15  # Outside bounds
+    @lru_cache(maxsize=100000)
+    def _get_cost_quantized(self, qx_milli: int, qy_milli: int) -> float:
+        qx = qx_milli / 1000.0
+        qy = qy_milli / 1000.0
+        if not self.is_within_bounds(qx, qy):
+            return 1e15
+        if self.tree is None:
+            return 0.0
+        dist, _ = self.tree.query([qx, qy], distance_upper_bound=self.safety_threshold)
+        if dist >= self.safety_threshold:
+            return 0.0
+        safe_dist = max(dist, 0.1)
+        return float(self.k / (safe_dist ** 2))

inire/router/pathfinder.py

@@ -1,13 +1,14 @@
 from __future__ import annotations
 
 import logging
-import time
 import random
+import time
 from dataclasses import dataclass
-from typing import TYPE_CHECKING, Callable, Literal, Any
+from typing import TYPE_CHECKING, Any, Callable, Literal
 
-from inire.router.astar import route_astar, AStarMetrics
-from inire.constants import TOLERANCE_LINEAR
+import numpy
+
+from inire.router.astar import AStarMetrics, route_astar
 
 if TYPE_CHECKING:
     from inire.geometry.components import ComponentResult
@@ -20,52 +21,24 @@ logger = logging.getLogger(__name__)
 
 @dataclass
 class RoutingResult:
-    """
-    Result of a single net routing operation.
-    """
     net_id: str
-    """ Identifier for the net """
-
     path: list[ComponentResult]
-    """ List of moves forming the path """
-
     is_valid: bool
-    """ Whether the path is collision-free and reached the target """
-
     collisions: int
-    """ Number of detected collisions/overlaps """
-
     reached_target: bool = False
-    """ Whether the final port matches the target port """
 
 
 class PathFinder:
-    """
-    Multi-net router using Negotiated Congestion.
-    """
-    __slots__ = ('context', 'metrics', 'max_iterations', 'base_congestion_penalty', 
-                 'use_tiered_strategy', 'congestion_multiplier', 'accumulated_expanded_nodes', 'warm_start')
-
-    context: AStarContext
-    """ The A* persistent state (config, caches, evaluator) """
-
-    metrics: AStarMetrics
-    """ Performance metrics for search operations """
-
-    max_iterations: int
-    """ Maximum number of rip-up and reroute iterations """
-
-    base_congestion_penalty: float
-    """ Starting penalty for overlaps """
-
-    congestion_multiplier: float
-    """ Multiplier for congestion penalty per iteration """
-
-    use_tiered_strategy: bool
-    """ If True, use simpler collision models in early iterations for speed """
-
-    warm_start: Literal['shortest', 'longest', 'user'] | None
-    """ Heuristic sorting for the initial greedy pass """
+    __slots__ = (
+        "context",
+        "metrics",
+        "max_iterations",
+        "base_congestion_penalty",
+        "use_tiered_strategy",
+        "congestion_multiplier",
+        "accumulated_expanded_nodes",
+        "warm_start",
+    )
 
     def __init__(
         self,
@@ -75,20 +48,8 @@ class PathFinder:
         base_congestion_penalty: float = 100.0,
         congestion_multiplier: float = 1.5,
         use_tiered_strategy: bool = True,
-            warm_start: Literal['shortest', 'longest', 'user'] | None = 'shortest',
+        warm_start: Literal["shortest", "longest", "user"] | None = "shortest",
     ) -> None:
-        """
-        Initialize the PathFinder.
-
-        Args:
-            context: The A* search context (evaluator, config, caches).
-            metrics: Optional metrics container.
-            max_iterations: Maximum number of rip-up and reroute iterations.
-            base_congestion_penalty: Starting penalty for overlaps.
-            congestion_multiplier: Multiplier for congestion penalty per iteration.
-            use_tiered_strategy: Whether to use simplified collision models in early iterations.
-            warm_start: Initial ordering strategy for a fast greedy pass.
-        """
         self.context = context
         self.metrics = metrics if metrics is not None else AStarMetrics()
         self.max_iterations = max_iterations
@@ -96,7 +57,7 @@ class PathFinder:
         self.congestion_multiplier = congestion_multiplier
         self.use_tiered_strategy = use_tiered_strategy
         self.warm_start = warm_start
-        self.accumulated_expanded_nodes: list[tuple[float, float, float]] = []
+        self.accumulated_expanded_nodes: list[tuple[int, int, int]] = []
 
     @property
     def cost_evaluator(self) -> CostEvaluator:
@@ -106,71 +67,58 @@ class PathFinder:
         self,
         netlist: dict[str, tuple[Port, Port]],
         net_widths: dict[str, float],
-            order: Literal['shortest', 'longest', 'user']
+        order: Literal["shortest", "longest", "user"],
     ) -> dict[str, list[ComponentResult]]:
-        """
-        Internal greedy pass: route nets sequentially and freeze them as static.
-        """
         all_net_ids = list(netlist.keys())
-        if order != 'user':
-            def get_dist(nid):
-                s, t = netlist[nid]
-                return abs(t.x - s.x) + abs(t.y - s.y)
-            all_net_ids.sort(key=get_dist, reverse=(order == 'longest'))
-            
-        greedy_paths = {}
-        temp_obj_ids = []
-        
-        logger.info(f"PathFinder: Starting Greedy Warm-Start ({order} order)...")
+        if order != "user":
+            all_net_ids.sort(
+                key=lambda nid: abs(netlist[nid][1].x - netlist[nid][0].x) + abs(netlist[nid][1].y - netlist[nid][0].y),
+                reverse=(order == "longest"),
+            )
 
+        greedy_paths: dict[str, list[ComponentResult]] = {}
+        temp_obj_ids: list[int] = []
+        greedy_node_limit = min(self.context.config.node_limit, 2000)
         for net_id in all_net_ids:
             start, target = netlist[net_id]
             width = net_widths.get(net_id, 2.0)
-            
-            # Heuristic max cost for fail-fast
             h_start = self.cost_evaluator.h_manhattan(start, target)
             max_cost_limit = max(h_start * 3.0, 2000.0)
-            
             path = route_astar(
-                start, target, width, context=self.context, metrics=self.metrics,
-                net_id=net_id, skip_congestion=True, max_cost=max_cost_limit
+                start,
+                target,
+                width,
+                context=self.context,
+                metrics=self.metrics,
+                net_id=net_id,
+                skip_congestion=True,
+                max_cost=max_cost_limit,
+                self_collision_check=True,
+                node_limit=greedy_node_limit,
             )
-            
-            if path:
+            if not path:
+                continue
             greedy_paths[net_id] = path
-                # Freeze as static
             for res in path:
                 geoms = res.actual_geometry if res.actual_geometry is not None else res.geometry
-                    for poly in geoms:
-                        obj_id = self.cost_evaluator.collision_engine.add_static_obstacle(poly)
+                dilated_geoms = res.dilated_actual_geometry if res.dilated_actual_geometry else res.dilated_geometry
+                for i, poly in enumerate(geoms):
+                    dilated = dilated_geoms[i] if dilated_geoms else None
+                    obj_id = self.cost_evaluator.collision_engine.add_static_obstacle(poly, dilated_geometry=dilated)
                     temp_obj_ids.append(obj_id)
+            self.context.clear_static_caches()
 
-        # Clean up temporary static obstacles
         for obj_id in temp_obj_ids:
             self.cost_evaluator.collision_engine.remove_static_obstacle(obj_id)
-            
-        logger.info(f"PathFinder: Greedy Warm-Start finished. Seeding {len(greedy_paths)}/{len(netlist)} nets.")
         return greedy_paths
 
     def _has_self_collision(self, path: list[ComponentResult]) -> bool:
-        """
-        Quickly check if a path intersects itself.
-        """
-        if not path:
-            return False
-            
-        num_components = len(path)
-        for i in range(num_components):
-            comp_i = path[i]
+        for i, comp_i in enumerate(path):
             tb_i = comp_i.total_bounds
-            for j in range(i + 2, num_components): # Skip immediate neighbors
+            for j in range(i + 2, len(path)):
                 comp_j = path[j]
                 tb_j = comp_j.total_bounds
-                
-                # AABB Check
-                if (tb_i[0] < tb_j[2] and tb_i[2] > tb_j[0] and
-                    tb_i[1] < tb_j[3] and tb_i[3] > tb_j[1]):
-                    # Real geometry check
+                if tb_i[0] < tb_j[2] and tb_i[2] > tb_j[0] and tb_i[1] < tb_j[3] and tb_i[3] > tb_j[1]:
                     for p_i in comp_i.geometry:
                         for p_j in comp_j.geometry:
                             if p_i.intersects(p_j) and not p_i.touches(p_j):
@@ -184,26 +132,10 @@ class PathFinder:
         store_expanded: bool = False,
         iteration_callback: Callable[[int, dict[str, RoutingResult]], None] | None = None,
         shuffle_nets: bool = False,
-            sort_nets: Literal['shortest', 'longest', 'user', None] = None,
+        sort_nets: Literal["shortest", "longest", "user", None] = None,
         initial_paths: dict[str, list[ComponentResult]] | None = None,
         seed: int | None = None,
     ) -> dict[str, RoutingResult]:
-        """
-        Route all nets in the netlist using Negotiated Congestion.
-
-        Args:
-            netlist: Mapping of net_id to (start_port, target_port).
-            net_widths: Mapping of net_id to waveguide width.
-            store_expanded: Whether to store expanded nodes for ALL iterations and nets.
-            iteration_callback: Optional callback(iteration_idx, current_results).
-            shuffle_nets: Whether to randomize the order of nets each iteration.
-            sort_nets: Heuristic sorting for the initial iteration order (overrides self.warm_start).
-            initial_paths: Pre-computed paths to use for Iteration 0 (overrides warm_start).
-            seed: Optional seed for randomization (enables reproducibility).
-
-        Returns:
-            Mapping of net_id to RoutingResult.
-        """
         results: dict[str, RoutingResult] = {}
         self.cost_evaluator.congestion_penalty = self.base_congestion_penalty
         self.accumulated_expanded_nodes = []
@@ -212,63 +144,44 @@ class PathFinder:
         start_time = time.monotonic()
         num_nets = len(netlist)
         session_timeout = max(60.0, 10.0 * num_nets * self.max_iterations)
-
         all_net_ids = list(netlist.keys())
-        needs_sc = set()  # Nets requiring self-collision avoidance
+        needs_sc: set[str] = set()
 
-        # Determine initial paths (Warm Start)
         if initial_paths is None:
             ws_order = sort_nets if sort_nets is not None else self.warm_start
             if ws_order is not None:
                 initial_paths = self._perform_greedy_pass(netlist, net_widths, ws_order)
                 self.context.clear_static_caches()
 
-        # Apply initial sorting heuristic if requested (for the main NC loop)
-        if sort_nets:
-            def get_dist(nid):
-                s, t = netlist[nid]
-                return abs(t.x - s.x) + abs(t.y - s.y)
-            
-            if sort_nets != 'user':
-                 all_net_ids.sort(key=get_dist, reverse=(sort_nets == 'longest'))
+        if sort_nets and sort_nets != "user":
+            all_net_ids.sort(
+                key=lambda nid: abs(netlist[nid][1].x - netlist[nid][0].x) + abs(netlist[nid][1].y - netlist[nid][0].y),
+                reverse=(sort_nets == "longest"),
+            )
 
         for iteration in range(self.max_iterations):
             any_congestion = False
-            # Clear accumulation for this iteration so callback gets fresh data
             self.accumulated_expanded_nodes = []
             self.metrics.reset_per_route()
 
-            logger.info(f'PathFinder Iteration {iteration}...')
-
-            # 0. Shuffle nets if requested
-            if shuffle_nets:
-                # Use a new seed based on iteration for deterministic different orders
+            if shuffle_nets and (iteration > 0 or initial_paths is None):
                 it_seed = (seed + iteration) if seed is not None else None
                 random.Random(it_seed).shuffle(all_net_ids)
 
-            # Sequence through nets
             for net_id in all_net_ids:
                 start, target = netlist[net_id]
-                # Timeout check
-                elapsed = time.monotonic() - start_time
-                if elapsed > session_timeout:
-                    logger.warning(f'PathFinder TIMEOUT after {elapsed:.2f}s')
-                    return self._finalize_results(results, netlist)
+                if time.monotonic() - start_time > session_timeout:
+                    self.cost_evaluator.collision_engine.dynamic_tree = None
+                    self.cost_evaluator.collision_engine._ensure_dynamic_tree()
+                    return self.verify_all_nets(results, netlist)
 
                 width = net_widths.get(net_id, 2.0)
-
-                # 1. Rip-up existing path
                 self.cost_evaluator.collision_engine.remove_path(net_id)
+                path: list[ComponentResult] | None = None
 
-                # 2. Reroute or Use Initial Path
-                path = None
-                
-                # Warm Start Logic: Use provided path for Iteration 0
                 if iteration == 0 and initial_paths and net_id in initial_paths:
                     path = initial_paths[net_id]
-                    logger.debug(f'  Net {net_id} used Warm Start path.')
                 else:
-                    # Standard Routing Logic
                     target_coll_model = self.context.config.bend_collision_type
                     coll_model = target_coll_model
                     skip_cong = False
@@ -277,41 +190,36 @@ class PathFinder:
                         if target_coll_model == "arc":
                             coll_model = "clipped_bbox"
 
-                    base_node_limit = self.context.config.node_limit
-                    current_node_limit = base_node_limit
-                    
-                    net_start = time.monotonic()
-                    
                     path = route_astar(
-                        start, target, width, context=self.context, metrics=self.metrics,
-                        net_id=net_id, bend_collision_type=coll_model, return_partial=True, 
-                        store_expanded=store_expanded, skip_congestion=skip_cong, 
+                        start,
+                        target,
+                        width,
+                        context=self.context,
+                        metrics=self.metrics,
+                        net_id=net_id,
+                        bend_collision_type=coll_model,
+                        return_partial=True,
+                        store_expanded=store_expanded,
+                        skip_congestion=skip_cong,
                         self_collision_check=(net_id in needs_sc),
-                        node_limit=current_node_limit
+                        node_limit=self.context.config.node_limit,
                     )
 
                     if store_expanded and self.metrics.last_expanded_nodes:
                         self.accumulated_expanded_nodes.extend(self.metrics.last_expanded_nodes)
 
-                    logger.debug(f'  Net {net_id} routed in {time.monotonic() - net_start:.4f}s using {coll_model}')
+                if not path:
+                    results[net_id] = RoutingResult(net_id, [], False, 0, reached_target=False)
+                    any_congestion = True
+                    continue
 
-                if path:
-                    # Check if reached exactly (relative to snapped target)
                 last_p = path[-1].end_port
-                    snap = self.context.config.snap_size
-                    from inire.geometry.components import snap_search_grid
-                    reached = (abs(last_p.x - snap_search_grid(target.x, snap)) < TOLERANCE_LINEAR and
-                               abs(last_p.y - snap_search_grid(target.y, snap)) < TOLERANCE_LINEAR and
-                               abs(last_p.orientation - target.orientation) < 0.1)
+                reached = last_p == target
 
-                    # Check for self-collision if not already handled by router
-                    if reached and net_id not in needs_sc:
-                         if self._has_self_collision(path):
-                              logger.info(f'  Net {net_id} detected self-collision. Enabling protection for next iteration.')
+                if reached and net_id not in needs_sc and self._has_self_collision(path):
                     needs_sc.add(net_id)
                     any_congestion = True
 
-                    # 3. Add to index (even if partial) so other nets negotiate around it
                 all_geoms = []
                 all_dilated = []
                 for res in path:
@@ -321,120 +229,44 @@ class PathFinder:
                     else:
                         dilation = self.cost_evaluator.collision_engine.clearance / 2.0
                         all_dilated.extend([p.buffer(dilation) for p in res.geometry])
-                            
                 self.cost_evaluator.collision_engine.add_path(net_id, all_geoms, dilated_geometry=all_dilated)
 
-                    # Check if this new path has any congestion
                 collision_count = 0
                 if reached:
-                        verif_geoms = []
-                        verif_dilated = []
-                        for res in path:
-                            is_proxy = (res.actual_geometry is not None)
-                            g = res.actual_geometry if is_proxy else res.geometry
-                            verif_geoms.extend(g)
+                    is_valid, collision_count = self.cost_evaluator.collision_engine.verify_path(net_id, path)
+                    any_congestion = any_congestion or not is_valid
 
-                            if is_proxy:
-                                if res.dilated_actual_geometry:
-                                    verif_dilated.extend(res.dilated_actual_geometry)
-                                else:
-                                    dilation = self.cost_evaluator.collision_engine.clearance / 2.0
-                                    verif_dilated.extend([p.buffer(dilation) for p in g])
-                            else:
-                                if res.dilated_geometry:
-                                    verif_dilated.extend(res.dilated_geometry)
-                                else:
-                                    dilation = self.cost_evaluator.collision_engine.clearance / 2.0
-                                    verif_dilated.extend([p.buffer(dilation) for p in g])
-
-                        self.cost_evaluator.collision_engine._ensure_dynamic_tree()
-                        if self.cost_evaluator.collision_engine.dynamic_tree:
-                            # Vectorized query for all polygons in the path
-                            res_indices, tree_indices = self.cost_evaluator.collision_engine.dynamic_tree.query(verif_dilated, predicate='intersects')
-                            for hit_idx in tree_indices:
-                                obj_id = self.cost_evaluator.collision_engine.dynamic_obj_ids[hit_idx]
-                                other_net_id, _ = self.cost_evaluator.collision_engine.dynamic_geometries[obj_id]
-                                if other_net_id != net_id:
-                                    collision_count += 1
-
-                        if collision_count > 0:
-                            any_congestion = True
-
-                    logger.debug(f'    Net {net_id}: reached={reached}, collisions={collision_count}')
-                    results[net_id] = RoutingResult(net_id, path, (collision_count == 0 and reached), collision_count, reached_target=reached)
-                else:
-                    results[net_id] = RoutingResult(net_id, [], False, 0, reached_target=False)
-                    any_congestion = True # Total failure might need a retry with different ordering
+                results[net_id] = RoutingResult(net_id, path, reached and collision_count == 0, collision_count, reached_target=reached)
 
             if iteration_callback:
                 iteration_callback(iteration, results)
-
             if not any_congestion:
                 break
-
             self.cost_evaluator.congestion_penalty *= self.congestion_multiplier
 
-        return self._finalize_results(results, netlist)
+        self.cost_evaluator.collision_engine.dynamic_tree = None
+        self.cost_evaluator.collision_engine._ensure_dynamic_tree()
+        return self.verify_all_nets(results, netlist)
 
-    def _finalize_results(
+    def verify_all_nets(
         self,
         results: dict[str, RoutingResult],
         netlist: dict[str, tuple[Port, Port]],
     ) -> dict[str, RoutingResult]:
-        """
-        Final check: re-verify all nets against the final static paths.
-        """
-        logger.debug(f'Finalizing results for nets: {list(results.keys())}')
-        final_results = {}
-        for net_id in netlist:
+        final_results: dict[str, RoutingResult] = {}
+        for net_id, (_, target_p) in netlist.items():
             res = results.get(net_id)
             if not res or not res.path:
                 final_results[net_id] = RoutingResult(net_id, [], False, 0)
                 continue
-            
-            if not res.reached_target:
-                # Skip re-verification for partial paths to avoid massive performance hit
-                final_results[net_id] = res
-                continue
-
-            collision_count = 0
-            verif_geoms = []
-            verif_dilated = []
-            for comp in res.path:
-                is_proxy = (comp.actual_geometry is not None)
-                g = comp.actual_geometry if is_proxy else comp.geometry
-                verif_geoms.extend(g)
-                if is_proxy:
-                    if comp.dilated_actual_geometry:
-                        verif_dilated.extend(comp.dilated_actual_geometry)
-                    else:
-                        dilation = self.cost_evaluator.collision_engine.clearance / 2.0
-                        verif_dilated.extend([p.buffer(dilation) for p in g])
-                else:
-                    if comp.dilated_geometry:
-                        verif_dilated.extend(comp.dilated_geometry)
-                    else:
-                        dilation = self.cost_evaluator.collision_engine.clearance / 2.0
-                        verif_dilated.extend([p.buffer(dilation) for p in g])
-
-            self.cost_evaluator.collision_engine._ensure_dynamic_tree()
-            if self.cost_evaluator.collision_engine.dynamic_tree:
-                # Vectorized query
-                res_indices, tree_indices = self.cost_evaluator.collision_engine.dynamic_tree.query(verif_dilated, predicate='intersects')
-                for hit_idx in tree_indices:
-                    obj_id = self.cost_evaluator.collision_engine.dynamic_obj_ids[hit_idx]
-                    other_net_id, _ = self.cost_evaluator.collision_engine.dynamic_geometries[obj_id]
-                    if other_net_id != net_id:
-                        collision_count += 1
-
-            target_p = netlist[net_id][1]
             last_p = res.path[-1].end_port
-            snap = self.context.config.snap_size
-            from inire.geometry.components import snap_search_grid
-            reached = (abs(last_p.x - snap_search_grid(target_p.x, snap)) < TOLERANCE_LINEAR and
-                       abs(last_p.y - snap_search_grid(target_p.y, snap)) < TOLERANCE_LINEAR and
-                       abs(last_p.orientation - target_p.orientation) < 0.1)
-
-            final_results[net_id] = RoutingResult(net_id, res.path, (collision_count == 0 and reached), collision_count, reached_target=reached)
-
+            reached = last_p == target_p
+            is_valid, collisions = self.cost_evaluator.collision_engine.verify_path(net_id, res.path)
+            final_results[net_id] = RoutingResult(
+                net_id=net_id,
+                path=res.path,
+                is_valid=(is_valid and reached),
+                collisions=collisions,
+                reached_target=reached,
+            )
         return final_results

inire/router/visibility.py

@@ -16,7 +16,7 @@ class VisibilityManager:
     """
     Manages corners of static obstacles for sparse A* / Visibility Graph jumps.
     """
-    __slots__ = ('collision_engine', 'corners', 'corner_index', '_corner_graph', '_static_visibility_cache')
+    __slots__ = ('collision_engine', 'corners', 'corner_index', '_corner_graph', '_static_visibility_cache', '_built_static_version')
 
     def __init__(self, collision_engine: CollisionEngine) -> None:
         self.collision_engine = collision_engine
@@ -24,12 +24,28 @@ class VisibilityManager:
         self.corner_index = rtree.index.Index()
         self._corner_graph: dict[int, list[tuple[float, float, float]]] = {}
         self._static_visibility_cache: dict[tuple[int, int], list[tuple[float, float, float]]] = {}
+        self._built_static_version = -1
         self._build()
 
+    def clear_cache(self) -> None:
+        """
+        Reset all static visibility data.
+        """
+        self.corners = []
+        self.corner_index = rtree.index.Index()
+        self._corner_graph = {}
+        self._static_visibility_cache = {}
+        self._build()
+
+    def _ensure_current(self) -> None:
+        if self._built_static_version != self.collision_engine._static_version:
+            self.clear_cache()
+
     def _build(self) -> None:
         """
         Extract corners and pre-compute corner-to-corner visibility.
         """
+        self._built_static_version = self.collision_engine._static_version
         raw_corners = []
         for obj_id, poly in self.collision_engine.static_dilated.items():
             coords = list(poly.exterior.coords)
@@ -45,7 +61,7 @@ class VisibilityManager:
         if not raw_corners:
             return
 
-        # Deduplicate and snap to 1nm
+        # Deduplicate repeated corner coordinates
         seen = set()
         for x, y in raw_corners:
             sx, sy = round(x, 3), round(y, 3)
@@ -81,6 +97,7 @@ class VisibilityManager:
         Find all corners visible from the origin.
         Returns list of (x, y, distance).
         """
+        self._ensure_current()
         if max_dist < 0:
             return []
             

inire/tests/test_astar.py

@@ -1,6 +1,8 @@
 import pytest
 from shapely.geometry import Polygon
 
+import inire.router.astar as astar_module
+from inire.geometry.components import SBend, Straight
 from inire.geometry.collision import CollisionEngine
 from inire.geometry.primitives import Port
 from inire.router.astar import AStarContext, route_astar
@@ -19,7 +21,7 @@ def basic_evaluator() -> CostEvaluator:
 
 
 def test_astar_straight(basic_evaluator: CostEvaluator) -> None:
-    context = AStarContext(basic_evaluator, snap_size=1.0)
+    context = AStarContext(basic_evaluator)
     start = Port(0, 0, 0)
     target = Port(50, 0, 0)
     path = route_astar(start, target, net_width=2.0, context=context)
@@ -35,7 +37,7 @@ def test_astar_straight(basic_evaluator: CostEvaluator) -> None:
 
 
 def test_astar_bend(basic_evaluator: CostEvaluator) -> None:
-    context = AStarContext(basic_evaluator, snap_size=1.0, bend_radii=[10.0])
+    context = AStarContext(basic_evaluator, bend_radii=[10.0])
     start = Port(0, 0, 0)
     # 20um right, 20um up. Needs a 10um bend and a 10um bend.
     target = Port(20, 20, 0)
@@ -56,7 +58,7 @@ def test_astar_obstacle(basic_evaluator: CostEvaluator) -> None:
     basic_evaluator.collision_engine.add_static_obstacle(obstacle)
     basic_evaluator.danger_map.precompute([obstacle])
 
-    context = AStarContext(basic_evaluator, snap_size=1.0, bend_radii=[10.0], node_limit=1000000)
+    context = AStarContext(basic_evaluator, bend_radii=[10.0], node_limit=1000000)
     start = Port(0, 0, 0)
     target = Port(60, 0, 0)
     path = route_astar(start, target, net_width=2.0, context=context)
@@ -70,20 +72,126 @@ def test_astar_obstacle(basic_evaluator: CostEvaluator) -> None:
     assert validation["total_length"] > 50.0
 
 
-def test_astar_snap_to_target_lookahead(basic_evaluator: CostEvaluator) -> None:
-    context = AStarContext(basic_evaluator, snap_size=1.0)
-    # Target is NOT on 1um grid
+def test_astar_uses_integerized_ports(basic_evaluator: CostEvaluator) -> None:
+    context = AStarContext(basic_evaluator)
     start = Port(0, 0, 0)
     target = Port(10.1, 0, 0)
     path = route_astar(start, target, net_width=2.0, context=context)
 
     assert path is not None
     result = RoutingResult(net_id="test", path=path, is_valid=True, collisions=0)
-    
-    # Under the new Enforce Grid policy, the router snaps the target internally to 10.0.
-    # We validate against the snapped target.
-    from inire.geometry.components import snap_search_grid
-    target_snapped = Port(snap_search_grid(target.x, 1.0), snap_search_grid(target.y, 1.0), target.orientation, snap=False)
-    validation = validate_routing_result(result, [], clearance=2.0, expected_start=start, expected_end=target_snapped)
+    assert target.x == 10
+    validation = validate_routing_result(result, [], clearance=2.0, expected_start=start, expected_end=target)
 
     assert validation["is_valid"], f"Validation failed: {validation.get('reason')}"
+
+
+def test_expand_moves_only_shortens_consecutive_straights(
+    basic_evaluator: CostEvaluator,
+    monkeypatch: pytest.MonkeyPatch,
+) -> None:
+    context = AStarContext(basic_evaluator, min_straight_length=5.0, max_straight_length=100.0)
+    prev_result = Straight.generate(Port(0, 0, 0), 20.0, width=2.0, dilation=1.0)
+    current = astar_module.AStarNode(
+        prev_result.end_port,
+        g_cost=prev_result.length,
+        h_cost=0.0,
+        component_result=prev_result,
+    )
+
+    emitted: list[tuple[str, tuple]] = []
+
+    def fake_process_move(*args, **kwargs) -> None:
+        emitted.append((args[9], args[10]))
+
+    monkeypatch.setattr(astar_module, "process_move", fake_process_move)
+
+    astar_module.expand_moves(
+        current,
+        Port(80, 0, 0),
+        net_width=2.0,
+        net_id="test",
+        open_set=[],
+        closed_set={},
+        context=context,
+        metrics=astar_module.AStarMetrics(),
+        congestion_cache={},
+    )
+
+    straight_lengths = [params[0] for move_class, params in emitted if move_class == "S"]
+    assert straight_lengths
+    assert all(length < prev_result.length for length in straight_lengths)
+
+
+def test_expand_moves_does_not_chain_sbends(
+    basic_evaluator: CostEvaluator,
+    monkeypatch: pytest.MonkeyPatch,
+) -> None:
+    context = AStarContext(basic_evaluator, sbend_radii=[10.0], sbend_offsets=[5.0], max_straight_length=100.0)
+    prev_result = SBend.generate(Port(0, 0, 0), 5.0, 10.0, width=2.0, dilation=1.0)
+    current = astar_module.AStarNode(
+        prev_result.end_port,
+        g_cost=prev_result.length,
+        h_cost=0.0,
+        component_result=prev_result,
+    )
+
+    emitted: list[str] = []
+
+    def fake_process_move(*args, **kwargs) -> None:
+        emitted.append(args[9])
+
+    monkeypatch.setattr(astar_module, "process_move", fake_process_move)
+
+    astar_module.expand_moves(
+        current,
+        Port(60, 10, 0),
+        net_width=2.0,
+        net_id="test",
+        open_set=[],
+        closed_set={},
+        context=context,
+        metrics=astar_module.AStarMetrics(),
+        congestion_cache={},
+    )
+
+    assert "SB" not in emitted
+    assert emitted
+
+
+def test_expand_moves_adds_sbend_aligned_straight_stop_points(
+    basic_evaluator: CostEvaluator,
+    monkeypatch: pytest.MonkeyPatch,
+) -> None:
+    context = AStarContext(
+        basic_evaluator,
+        bend_radii=[10.0],
+        sbend_radii=[10.0],
+        max_straight_length=150.0,
+    )
+    current = astar_module.AStarNode(Port(0, 0, 0), g_cost=0.0, h_cost=0.0)
+
+    emitted: list[tuple[str, tuple]] = []
+
+    def fake_process_move(*args, **kwargs) -> None:
+        emitted.append((args[9], args[10]))
+
+    monkeypatch.setattr(astar_module, "process_move", fake_process_move)
+
+    astar_module.expand_moves(
+        current,
+        Port(100, 10, 0),
+        net_width=2.0,
+        net_id="test",
+        open_set=[],
+        closed_set={},
+        context=context,
+        metrics=astar_module.AStarMetrics(),
+        congestion_cache={},
+    )
+
+    straight_lengths = {params[0] for move_class, params in emitted if move_class == "S"}
+    sbend_span = astar_module._sbend_forward_span(10.0, 10.0)
+    assert sbend_span is not None
+    assert int(round(100.0 - sbend_span)) in straight_lengths
+    assert int(round(100.0 - 2.0 * sbend_span)) in straight_lengths

inire/tests/test_clearance_precision.py

@@ -0,0 +1,92 @@
+import pytest
+import numpy
+from shapely.geometry import Polygon
+from inire.geometry.collision import CollisionEngine
+from inire.geometry.primitives import Port
+from inire.geometry.components import Straight
+from inire.router.cost import CostEvaluator
+from inire.router.danger_map import DangerMap
+from inire.router.astar import AStarContext
+from inire.router.pathfinder import PathFinder, RoutingResult
+
+def test_clearance_thresholds():
+    """
+    Check that clearance is correctly calculated:
+    two paths slightly beyond, exactly at, and slightly violating.
+    """
+    # Clearance = 2.0, Width = 2.0
+    # Required Centerline-to-Centerline = (2+2)/2 + 2.0 = 4.0
+    ce = CollisionEngine(clearance=2.0)
+    
+    # Net 1: Centerline at y=0
+    p1 = Port(0, 0, 0)
+    res1 = Straight.generate(p1, 50.0, width=2.0, dilation=1.0)
+    ce.add_path("net1", res1.geometry, dilated_geometry=res1.dilated_geometry)
+    
+    # Net 2: Parallel to Net 1
+    # 1. Beyond minimum spacing: y=5. Gap = 5 - 2 = 3 > 2. OK.
+    p2_ok = Port(0, 5, 0)
+    res2_ok = Straight.generate(p2_ok, 50.0, width=2.0, dilation=1.0)
+    is_v, count = ce.verify_path("net2", [res2_ok])
+    assert is_v, f"Gap 3 should be valid, but got {count} collisions"
+    
+    # 2. Exactly at: y=4.0. Gap = 4.0 - 2.0 = 2.0. OK.
+    p2_exact = Port(0, 4, 0)
+    res2_exact = Straight.generate(p2_exact, 50.0, width=2.0, dilation=1.0)
+    is_v, count = ce.verify_path("net2", [res2_exact])
+    assert is_v, f"Gap exactly 2.0 should be valid, but got {count} collisions"
+
+    # 3. Slightly violating: y=3.999. Gap = 3.999 - 2.0 = 1.999 < 2.0. FAIL.
+    p2_fail = Port(0, 3, 0)
+    res2_fail = Straight.generate(p2_fail, 50.0, width=2.0, dilation=1.0)
+    is_v, count = ce.verify_path("net2", [res2_fail])
+    assert not is_v, "Gap 1.999 should be invalid"
+    assert count > 0
+
+def test_verify_all_nets_cases():
+    """
+    Validate that verify_all_nets catches some common cases and doesn't flag reasonable non-failing cases.
+    """
+    engine = CollisionEngine(clearance=2.0)
+    danger_map = DangerMap(bounds=(0, 0, 100, 100))
+    danger_map.precompute([])
+    evaluator = CostEvaluator(collision_engine=engine, danger_map=danger_map)
+    context = AStarContext(cost_evaluator=evaluator)
+    pf = PathFinder(context, warm_start=None, max_iterations=1)
+
+    # Case 1: Parallel paths exactly at clearance (Should be VALID)
+    netlist_parallel_ok = {
+        "net1": (Port(0, 50, 0), Port(100, 50, 0)),
+        "net2": (Port(0, 54, 0), Port(100, 54, 0)),
+    }
+    net_widths = {"net1": 2.0, "net2": 2.0}
+    
+    results = pf.route_all(netlist_parallel_ok, net_widths)
+    assert results["net1"].is_valid, f"Exactly at clearance should be valid, collisions={results['net1'].collisions}"
+    assert results["net2"].is_valid
+
+    # Case 2: Parallel paths slightly within clearance (Should be INVALID)
+    netlist_parallel_fail = {
+        "net3": (Port(0, 20, 0), Port(100, 20, 0)),
+        "net4": (Port(0, 23, 0), Port(100, 23, 0)),
+    }
+    # Reset engine
+    engine.remove_path("net1")
+    engine.remove_path("net2")
+    
+    results_p = pf.route_all(netlist_parallel_fail, net_widths)
+    # verify_all_nets should flag both as invalid because they cross-collide
+    assert not results_p["net3"].is_valid
+    assert not results_p["net4"].is_valid
+
+    # Case 3: Crossing paths (Should be INVALID)
+    netlist_cross = {
+        "net5": (Port(0, 75, 0), Port(100, 75, 0)),
+        "net6": (Port(50, 0, 90), Port(50, 100, 90)),
+    }
+    engine.remove_path("net3")
+    engine.remove_path("net4")
+    
+    results_c = pf.route_all(netlist_cross, net_widths)
+    assert not results_c["net5"].is_valid
+    assert not results_c["net6"].is_valid

inire/tests/test_collision.py

@@ -2,6 +2,7 @@ from shapely.geometry import Polygon
 
 from inire.geometry.collision import CollisionEngine
 from inire.geometry.primitives import Port
+from inire.geometry.components import Straight
 
 
 def test_collision_detection() -> None:
@@ -38,7 +39,7 @@ def test_safety_zone() -> None:
     engine.add_static_obstacle(obstacle)
 
     # Port exactly on the boundary
-    start_port = Port(10.0, 12.0, 0)
+    start_port = Port(10, 12, 0)
 
     # Move starting from this port that overlaps the obstacle by 1nm
     # (Inside the 2nm safety zone)
@@ -59,3 +60,46 @@ def test_configurable_max_net_width() -> None:
     # Dilated test_poly bounds: (14, 19, 17, 26).
     # obstacle: (20, 20, 25, 25). No physical collision.
     assert not engine.is_collision(test_poly, net_width=2.0)
+
+
+def test_ray_cast_width_clearance() -> None:
+    # Clearance = 2.0um, Width = 2.0um.
+    # Centerline to obstacle edge must be >= W/2 + C = 1.0 + 2.0 = 3.0um.
+    engine = CollisionEngine(clearance=2.0)
+    
+    # Obstacle at x=10 to 20
+    obstacle = Polygon([(10, 0), (20, 0), (20, 100), (10, 100)])
+    engine.add_static_obstacle(obstacle)
+    
+    # 1. Parallel move at x=6. Gap = 10 - 6 = 4.0. Clearly OK.
+    start_ok = Port(6, 50, 90)
+    reach_ok = engine.ray_cast(start_ok, 90, max_dist=10.0, net_width=2.0)
+    assert reach_ok >= 10.0
+    
+    # 2. Parallel move at x=8. Gap = 10 - 8 = 2.0. COLLISION.
+    start_fail = Port(8, 50, 90)
+    reach_fail = engine.ray_cast(start_fail, 90, max_dist=10.0, net_width=2.0)
+    assert reach_fail < 10.0
+
+
+def test_check_move_static_clearance() -> None:
+    engine = CollisionEngine(clearance=2.0)
+    obstacle = Polygon([(10, 0), (20, 0), (20, 100), (10, 100)])
+    engine.add_static_obstacle(obstacle)
+    
+    # Straight move of length 10 at x=8 (Width 2.0)
+    # Gap = 10 - 8 = 2.0 < 3.0. COLLISION.
+    start = Port(8, 0, 90)
+    res = Straight.generate(start, 10.0, width=2.0, dilation=1.0) # dilation = C/2
+    
+    assert engine.check_move_static(res, start_port=start, net_width=2.0)
+    
+    # Move at x=7. Gap = 3.0 == minimum. OK.
+    start_ok = Port(7, 0, 90)
+    res_ok = Straight.generate(start_ok, 10.0, width=2.0, dilation=1.0)
+    assert not engine.check_move_static(res_ok, start_port=start_ok, net_width=2.0)
+    
+    # 3. Same exact-boundary case.
+    start_exact = Port(7, 0, 90)
+    res_exact = Straight.generate(start_exact, 10.0, width=2.0, dilation=1.0)
+    assert not engine.check_move_static(res_exact, start_port=start_exact, net_width=2.0)

inire/tests/test_components.py

@@ -8,7 +8,7 @@ def test_straight_generation() -> None:
     start = Port(0, 0, 0)
     length = 10.0
     width = 2.0
-    result = Straight.generate(start, length, width, snap_size=1.0)
+    result = Straight.generate(start, length, width)
 
     assert result.end_port.x == 10.0
     assert result.end_port.y == 0.0
@@ -29,13 +29,13 @@ def test_bend90_generation() -> None:
     width = 2.0
 
     # CW bend
-    result_cw = Bend90.generate(start, radius, width, direction="CW", snap_size=1.0)
+    result_cw = Bend90.generate(start, radius, width, direction="CW")
     assert result_cw.end_port.x == 10.0
     assert result_cw.end_port.y == -10.0
     assert result_cw.end_port.orientation == 270.0
 
     # CCW bend
-    result_ccw = Bend90.generate(start, radius, width, direction="CCW", snap_size=1.0)
+    result_ccw = Bend90.generate(start, radius, width, direction="CCW")
     assert result_ccw.end_port.x == 10.0
     assert result_ccw.end_port.y == 10.0
     assert result_ccw.end_port.orientation == 90.0
@@ -47,7 +47,7 @@ def test_sbend_generation() -> None:
     radius = 10.0
     width = 2.0
 
-    result = SBend.generate(start, offset, radius, width, snap_size=1.0)
+    result = SBend.generate(start, offset, radius, width)
     assert result.end_port.y == 5.0
     assert result.end_port.orientation == 0.0
     assert len(result.geometry) == 2 # Optimization: returns individual arcs
@@ -57,13 +57,27 @@ def test_sbend_generation() -> None:
         SBend.generate(start, 25.0, 10.0, 2.0)
 
 
+def test_sbend_generation_negative_offset_keeps_second_arc_below_centerline() -> None:
+    start = Port(0, 0, 0)
+    offset = -5.0
+    radius = 10.0
+    width = 2.0
+
+    result = SBend.generate(start, offset, radius, width)
+
+    assert result.end_port.y == -5.0
+    second_arc_minx, second_arc_miny, second_arc_maxx, second_arc_maxy = result.geometry[1].bounds
+    assert second_arc_maxy <= width / 2.0 + 1e-6
+    assert second_arc_miny < -width / 2.0
+
+
 def test_bend_collision_models() -> None:
     start = Port(0, 0, 0)
     radius = 10.0
     width = 2.0
 
     # 1. BBox model
-    res_bbox = Bend90.generate(start, radius, width, direction="CCW", collision_type="bbox", snap_size=1.0)
+    res_bbox = Bend90.generate(start, radius, width, direction="CCW", collision_type="bbox")
     # Arc CCW R=10 from (0,0,0) ends at (10,10,90).
     # Waveguide width is 2.0, so bbox will be slightly larger than (0,0,10,10)
     minx, miny, maxx, maxy = res_bbox.geometry[0].bounds
@@ -73,7 +87,7 @@ def test_bend_collision_models() -> None:
     assert maxy >= 10.0 - 1e-6
 
     # 2. Clipped BBox model
-    res_clipped = Bend90.generate(start, radius, width, direction="CCW", collision_type="clipped_bbox", clip_margin=1.0, snap_size=1.0)
+    res_clipped = Bend90.generate(start, radius, width, direction="CCW", collision_type="clipped_bbox", clip_margin=1.0)
     # Area should be less than full bbox
     assert res_clipped.geometry[0].area < res_bbox.geometry[0].area
 
@@ -84,11 +98,11 @@ def test_sbend_collision_models() -> None:
     radius = 10.0
     width = 2.0
 
-    res_bbox = SBend.generate(start, offset, radius, width, collision_type="bbox", snap_size=1.0)
+    res_bbox = SBend.generate(start, offset, radius, width, collision_type="bbox")
     # Geometry should be a list of individual bbox polygons for each arc
     assert len(res_bbox.geometry) == 2
 
-    res_arc = SBend.generate(start, offset, radius, width, collision_type="arc", snap_size=1.0)
+    res_arc = SBend.generate(start, offset, radius, width, collision_type="arc")
     area_bbox = sum(p.area for p in res_bbox.geometry)
     area_arc = sum(p.area for p in res_arc.geometry)
     assert area_bbox > area_arc
@@ -101,8 +115,7 @@ def test_sbend_continuity() -> None:
     radius = 20.0
     width = 1.0
 
-    # We use snap_size=1.0 so that (10-offset) = 6.0 is EXACTLY hit.
-    res = SBend.generate(start, offset, radius, width, snap_size=1.0)
+    res = SBend.generate(start, offset, radius, width)
 
     # Target orientation should be same as start
     assert abs(res.end_port.orientation - 90.0) < 1e-6
@@ -142,7 +155,7 @@ def test_component_transform_invariance() -> None:
     radius = 10.0
     width = 2.0
 
-    res0 = Bend90.generate(start0, radius, width, direction="CCW", snap_size=1.0)
+    res0 = Bend90.generate(start0, radius, width, direction="CCW")
 
     # Transform: Translate (10, 10) then Rotate 90
     dx, dy = 10.0, 5.0
@@ -153,7 +166,7 @@ def test_component_transform_invariance() -> None:
 
     # 2. Generate at transformed start
     start_transformed = rotate_port(translate_port(start0, dx, dy), angle)
-    res_transformed = Bend90.generate(start_transformed, radius, width, direction="CCW", snap_size=1.0)
+    res_transformed = Bend90.generate(start_transformed, radius, width, direction="CCW")
 
     assert abs(res_transformed.end_port.x - p_end_transformed.x) < 1e-6
     assert abs(res_transformed.end_port.y - p_end_transformed.y) < 1e-6

inire/tests/test_congestion.py

@@ -19,7 +19,7 @@ def basic_evaluator() -> CostEvaluator:
 
 
 def test_astar_sbend(basic_evaluator: CostEvaluator) -> None:
-    context = AStarContext(basic_evaluator, snap_size=1.0, sbend_offsets=[2.0, 5.0])
+    context = AStarContext(basic_evaluator, sbend_offsets=[2.0, 5.0])
     # Start at (0,0), target at (50, 2) -> 2um lateral offset
     # This matches one of our discretized SBend offsets.
     start = Port(0, 0, 0)
@@ -39,7 +39,7 @@ def test_astar_sbend(basic_evaluator: CostEvaluator) -> None:
 
 
 def test_pathfinder_negotiated_congestion_resolution(basic_evaluator: CostEvaluator) -> None:
-    context = AStarContext(basic_evaluator, snap_size=1.0, bend_radii=[5.0, 10.0])
+    context = AStarContext(basic_evaluator, bend_radii=[5.0, 10.0])
     # Increase base penalty to force detour immediately
     pf = PathFinder(context, max_iterations=10, base_congestion_penalty=1000.0)
 
@@ -59,5 +59,10 @@ def test_pathfinder_negotiated_congestion_resolution(basic_evaluator: CostEvalua
 
     results = pf.route_all(netlist, net_widths)
 
+    assert len(results) == 2
+    assert results["net1"].reached_target
+    assert results["net2"].reached_target
     assert results["net1"].is_valid
     assert results["net2"].is_valid
+    assert results["net1"].collisions == 0
+    assert results["net2"].collisions == 0

inire/tests/test_cost.py

@@ -1,3 +1,4 @@
+from shapely.geometry import Polygon
 from inire.geometry.collision import CollisionEngine
 from inire.geometry.primitives import Port
 from inire.router.cost import CostEvaluator
@@ -37,3 +38,30 @@ def test_cost_calculation() -> None:
     # Side check: 2*bp = 20.
     # Total = 1.1 * (20 + 40) = 66.0
     assert h_away >= h_90
+
+
+def test_danger_map_kd_tree_and_cache() -> None:
+    # Test that KD-Tree based danger map works and uses cache
+    bounds = (0, 0, 1000, 1000)
+    dm = DangerMap(bounds, resolution=1.0, safety_threshold=10.0)
+    
+    # Square obstacle at (100, 100) to (110, 110)
+    obstacle = Polygon([(100, 100), (110, 100), (110, 110), (100, 110)])
+    dm.precompute([obstacle])
+    
+    # 1. High cost near boundary
+    cost_near = dm.get_cost(100.5, 100.5)
+    assert cost_near > 1.0
+    
+    # 2. Zero cost far away
+    cost_far = dm.get_cost(500, 500)
+    assert cost_far == 0.0
+    
+    # 3. Check cache usage (internal detail check)
+    # We can check if calling it again is fast or just verify it returns same result
+    cost_near_2 = dm.get_cost(100.5, 100.5)
+    assert cost_near_2 == cost_near
+    
+    # 4. Out of bounds
+    assert dm.get_cost(-1, -1) >= 1e12
+

inire/tests/test_pathfinder.py

@@ -33,3 +33,25 @@ def test_pathfinder_parallel(basic_evaluator: CostEvaluator) -> None:
     assert results["net2"].is_valid
     assert results["net1"].collisions == 0
     assert results["net2"].collisions == 0
+
+
+def test_pathfinder_crossing_detection(basic_evaluator: CostEvaluator) -> None:
+    context = AStarContext(basic_evaluator)
+    # Force a crossing by setting low iterations and low penalty
+    pf = PathFinder(context, max_iterations=1, base_congestion_penalty=1.0, warm_start=None)
+
+    # Net 1: (0, 25) -> (100, 25) Horizontal
+    # Net 2: (50, 0) -> (50, 50) Vertical
+    netlist = {
+        "net1": (Port(0, 25, 0), Port(100, 25, 0)),
+        "net2": (Port(50, 0, 90), Port(50, 50, 90)),
+    }
+    net_widths = {"net1": 2.0, "net2": 2.0}
+
+    results = pf.route_all(netlist, net_widths)
+
+    # Both should be invalid because they cross
+    assert not results["net1"].is_valid
+    assert not results["net2"].is_valid
+    assert results["net1"].collisions > 0
+    assert results["net2"].collisions > 0

inire/tests/test_primitives.py

@@ -15,8 +15,8 @@ def port_strategy(draw: Any) -> Port:
 
 def test_port_snapping() -> None:
     p = Port(0.123456, 0.654321, 90)
-    assert p.x == 0.123
-    assert p.y == 0.654
+    assert p.x == 0
+    assert p.y == 1
 
 
 @given(p=port_strategy())
@@ -38,14 +38,13 @@ def test_port_transform_invariants(p: Port) -> None:
 )
 def test_translate_snapping(p: Port, dx: float, dy: float) -> None:
     p_trans = translate_port(p, dx, dy)
-    # Check that snapped result is indeed multiple of GRID_SNAP_UM (0.001 um = 1nm)
-    assert abs(p_trans.x * 1000 - round(p_trans.x * 1000)) < 1e-6
-    assert abs(p_trans.y * 1000 - round(p_trans.y * 1000)) < 1e-6
+    assert isinstance(p_trans.x, int)
+    assert isinstance(p_trans.y, int)
 
 
 def test_orientation_normalization() -> None:
     p = Port(0, 0, 360)
-    assert p.orientation == 0.0
+    assert p.orientation == 0
 
     p2 = Port(0, 0, -90)
-    assert p2.orientation == 270.0
+    assert p2.orientation == 270

inire/tests/test_variable_grid.py

@@ -3,64 +3,49 @@ from inire.geometry.primitives import Port
 from inire.router.astar import route_astar, AStarContext
 from inire.router.cost import CostEvaluator
 from inire.geometry.collision import CollisionEngine
-from inire.geometry.components import snap_search_grid
 
-class TestVariableGrid(unittest.TestCase):
+
+class TestIntegerPorts(unittest.TestCase):
     def setUp(self):
         self.ce = CollisionEngine(clearance=2.0)
         self.cost = CostEvaluator(self.ce)
 
-    def test_grid_1_0(self):
-        """ Test routing with a 1.0um grid. """
-        context = AStarContext(self.cost, snap_size=1.0)
-        start = Port(0.0, 0.0, 0.0)
-        # 12.3 should snap to 12.0 on a 1.0um grid
-        target = Port(12.3, 0.0, 0.0, snap=False)
+    def test_route_reaches_integer_target(self):
+        context = AStarContext(self.cost)
+        start = Port(0, 0, 0)
+        target = Port(12, 0, 0)
 
         path = route_astar(start, target, net_width=1.0, context=context)
 
         self.assertIsNotNone(path)
         last_port = path[-1].end_port
-        self.assertEqual(last_port.x, 12.0)
+        self.assertEqual(last_port.x, 12)
+        self.assertEqual(last_port.y, 0)
+        self.assertEqual(last_port.r, 0)
 
-        # Verify component relative grid coordinates
-        # rel_gx = round(x / snap)
-        # For x=12.0, snap=1.0 -> rel_gx=12
-        self.assertEqual(path[-1].rel_gx, 12)
-
-    def test_grid_2_5(self):
-        """ Test routing with a 2.5um grid. """
-        context = AStarContext(self.cost, snap_size=2.5)
+    def test_port_constructor_rounds_to_integer_lattice(self):
+        context = AStarContext(self.cost)
         start = Port(0.0, 0.0, 0.0)
-        # 7.5 is a multiple of 2.5, should be reached exactly
-        target = Port(7.5, 0.0, 0.0, snap=False)
+        target = Port(12.3, 0.0, 0.0)
 
         path = route_astar(start, target, net_width=1.0, context=context)
 
         self.assertIsNotNone(path)
+        self.assertEqual(target.x, 12)
         last_port = path[-1].end_port
-        self.assertEqual(last_port.x, 7.5)
+        self.assertEqual(last_port.x, 12)
 
-        # rel_gx = 7.5 / 2.5 = 3
-        self.assertEqual(path[-1].rel_gx, 3)
-
-    def test_grid_10_0(self):
-        """ Test routing with a large 10.0um grid. """
-        context = AStarContext(self.cost, snap_size=10.0)
+    def test_half_step_inputs_use_integerized_targets(self):
+        context = AStarContext(self.cost)
         start = Port(0.0, 0.0, 0.0)
-        # 15.0 should snap to 20.0 (ties usually round to even or nearest, 
-        # but 15.0 is exactly between 10 and 20. 
-        # snap_search_grid uses round(val/snap)*snap. round(1.5) is 2 in Python 3.
-        target = Port(15.0, 0.0, 0.0, snap=False)
+        target = Port(7.5, 0.0, 0.0)
 
         path = route_astar(start, target, net_width=1.0, context=context)
 
         self.assertIsNotNone(path)
+        self.assertEqual(target.x, 8)
         last_port = path[-1].end_port
-        self.assertEqual(last_port.x, 20.0)
-        
-        # rel_gx = 20.0 / 10.0 = 2
-        self.assertEqual(path[-1].rel_gx, 2)
+        self.assertEqual(last_port.x, 8)
 
 if __name__ == '__main__':
     unittest.main()

inire/utils/validation.py

@@ -47,11 +47,11 @@ def validate_routing_result(
     # Boundary check
     if expected_end:
         last_port = result.path[-1].end_port
-        dist_to_end = numpy.sqrt((last_port.x - expected_end.x)**2 + (last_port.y - expected_end.y)**2)
+        dist_to_end = numpy.sqrt(((last_port[:2] - expected_end[:2])**2).sum())
         if dist_to_end > 0.005:
             connectivity_errors.append(f"Final port position mismatch: {dist_to_end*1000:.2f}nm")
-        if abs(last_port.orientation - expected_end.orientation) > 0.1:
-            connectivity_errors.append(f"Final port orientation mismatch: {last_port.orientation} vs {expected_end.orientation}")
+        if abs(last_port[2] - expected_end[2]) > 0.1:
+            connectivity_errors.append(f"Final port orientation mismatch: {last_port[2]} vs {expected_end[2]}")
 
     # 2. Geometry Buffering
     dilation_half = clearance / 2.0

inire/utils/visualization.py

@@ -99,8 +99,8 @@ def plot_routing_results(
     if netlist:
         for net_id, (start_p, target_p) in netlist.items():
             for p in [start_p, target_p]:
-                rad = numpy.radians(p.orientation)
-                ax.quiver(p.x, p.y, numpy.cos(rad), numpy.sin(rad), color="black", 
+                rad = numpy.radians(p[2])
+                ax.quiver(*p[:2], numpy.cos(rad), numpy.sin(rad), color="black",
                           scale=25, width=0.004, pivot="tail", zorder=6)
 
     ax.set_xlim(bounds[0], bounds[2])
@@ -121,6 +121,7 @@ def plot_routing_results(
 def plot_danger_map(
     danger_map: DangerMap,
     ax: Axes | None = None,
+    resolution: float | None = None
 ) -> tuple[Figure, Axes]:
     """
     Plot the pre-computed danger map as a heatmap.
@@ -130,10 +131,30 @@ def plot_danger_map(
     else:
         fig = ax.get_figure()
 
+    # Generate a temporary grid for visualization
+    res = resolution if resolution is not None else max(1.0, (danger_map.maxx - danger_map.minx) / 200.0)
+    x_coords = numpy.arange(danger_map.minx + res/2, danger_map.maxx, res)
+    y_coords = numpy.arange(danger_map.miny + res/2, danger_map.maxy, res)
+    xv, yv = numpy.meshgrid(x_coords, y_coords, indexing='ij')
+
+    if danger_map.tree is not None:
+        points = numpy.stack([xv.ravel(), yv.ravel()], axis=1)
+        dists, _ = danger_map.tree.query(points, distance_upper_bound=danger_map.safety_threshold)
+
+        # Apply cost function
+        safe_dists = numpy.maximum(dists, 0.1)
+        grid_flat = numpy.where(
+            dists < danger_map.safety_threshold,
+            danger_map.k / (safe_dists**2),
+            0.0
+        )
+        grid = grid_flat.reshape(xv.shape)
+    else:
+        grid = numpy.zeros(xv.shape)
+
     # Need to transpose because grid is [x, y] and imshow expects [row, col] (y, x)
-    # Also origin='lower' to match coordinates
     im = ax.imshow(
-        danger_map.grid.T,
+        grid.T,
         origin='lower',
         extent=[danger_map.minx, danger_map.maxx, danger_map.miny, danger_map.maxy],
         cmap='YlOrRd',