diff --git a/masque/builder/pather.py b/masque/builder/pather.py
index 3478c32..e8804d1 100644
--- a/masque/builder/pather.py
+++ b/masque/builder/pather.py
@@ -415,8 +415,17 @@ class Pather(PortList):
                 self._apply_dead_fallback(portspec, length, jog, None, in_ptype, plug_into, out_rot=pi)
                 return self
 
-            self._traceL(portspec, ccw0, L1, **(kwargs | {'out_ptype': None}))
-            self._traceL(portspec, not ccw0, L2, **(kwargs | {'plug_into': plug_into}))
+            try:
+                out_port0, data0 = tool.planL(ccw0, L1, in_ptype=in_ptype, **(kwargs | {'out_ptype': None}))
+                out_port1, data1 = tool.planL(not ccw0, L2, in_ptype=out_port0.ptype, **kwargs)
+            except (BuildError, NotImplementedError):
+                if not self._dead:
+                    raise
+                self._apply_dead_fallback(portspec, length, jog, None, in_ptype, plug_into, out_rot=pi)
+                return self
+
+            self._apply_step('L', portspec, out_port0, data0, tool)
+            self._apply_step('L', portspec, out_port1, data1, tool, plug_into)
             return self
         if out_port is not None:
             self._apply_step('S', portspec, out_port, data, tool, plug_into)
@@ -436,14 +445,16 @@ class Pather(PortList):
             try:
                 R = self._get_tool_R(tool, ccw, in_ptype, **kwargs)
                 L1, L2 = length + R, abs(jog) - R
-                self._traceL(portspec, ccw, L1, **(kwargs | {'out_ptype': None}))
-                self._traceL(portspec, ccw, L2, **(kwargs | {'plug_into': plug_into}))
+                out_port0, data0 = tool.planL(ccw, L1, in_ptype=in_ptype, **(kwargs | {'out_ptype': None}))
+                out_port1, data1 = tool.planL(ccw, L2, in_ptype=out_port0.ptype, **kwargs)
             except (BuildError, NotImplementedError):
                 if not self._dead:
                     raise
                 self._apply_dead_fallback(portspec, length, jog, None, in_ptype, plug_into, out_rot=0)
                 return self
             else:
+                self._apply_step('L', portspec, out_port0, data0, tool)
+                self._apply_step('L', portspec, out_port1, data1, tool, plug_into)
                 return self
         if out_port is not None:
             self._apply_step('U', portspec, out_port, data, tool, plug_into)
diff --git a/masque/builder/tools.py b/masque/builder/tools.py
index 4a82b34..f8779bd 100644
--- a/masque/builder/tools.py
+++ b/masque/builder/tools.py
@@ -1031,7 +1031,7 @@ class AutoTool(Tool, metaclass=ABCMeta):
                 jog_remaining = jog - itrans_dxy[1] - otrans_dxy[1]
                 if sbend.jog_range[0] <= jog_remaining < sbend.jog_range[1]:
                     sbend_dxy = self._sbend2dxy(sbend, jog_remaining)
-                    success = numpy.isclose(length, sbend_dxy[0] + itrans_dxy[1] + otrans_dxy[1])
+                    success = numpy.isclose(length, sbend_dxy[0] + itrans_dxy[0] + otrans_dxy[0])
                     if success:
                         b_transition = None
                         straight_length = 0
@@ -1244,7 +1244,7 @@ class PathTool(Tool, metaclass=ABCMeta):
             port_names: tuple[str, str] = ('A', 'B'),
             **kwargs,                           # noqa: ARG002 (unused)
             ) -> Library:
-        out_port, dxy = self.planL(
+        out_port, _data = self.planL(
             ccw,
             length,
             in_ptype=in_ptype,
@@ -1252,7 +1252,12 @@ class PathTool(Tool, metaclass=ABCMeta):
             )
 
         tree, pat = Library.mktree(SINGLE_USE_PREFIX + 'traceL')
-        pat.path(layer=self.layer, width=self.width, vertices=[(0, 0), (length, 0)])
+        vertices: list[tuple[float, float]]
+        if ccw is None:
+            vertices = [(0.0, 0.0), (length, 0.0)]
+        else:
+            vertices = [(0.0, 0.0), (length, 0.0), tuple(out_port.offset)]
+        pat.path(layer=self.layer, width=self.width, vertices=vertices)
 
         if ccw is None:
             out_rot = pi
@@ -1263,7 +1268,7 @@ class PathTool(Tool, metaclass=ABCMeta):
 
         pat.ports = {
             port_names[0]: Port((0, 0), rotation=0, ptype=self.ptype),
-            port_names[1]: Port(dxy, rotation=out_rot, ptype=self.ptype),
+            port_names[1]: Port(out_port.offset, rotation=out_rot, ptype=self.ptype),
             }
 
         return tree
diff --git a/masque/shapes/path.py b/masque/shapes/path.py
index 3df55f4..3aa6f07 100644
--- a/masque/shapes/path.py
+++ b/masque/shapes/path.py
@@ -453,6 +453,8 @@ class Path(Shape):
     def scale_by(self, c: float) -> 'Path':
         self.vertices *= c
         self.width *= c
+        if self.cap_extensions is not None:
+            self.cap_extensions *= c
         return self
 
     def normalized_form(self, norm_value: float) -> normalized_shape_tuple:
@@ -476,13 +478,15 @@ class Path(Shape):
             reordered_vertices = rotated_vertices
 
         width0 = self.width / norm_value
+        cap_extensions0 = None if self.cap_extensions is None else tuple(float(v) / norm_value for v in self.cap_extensions)
 
-        return ((type(self), reordered_vertices.data.tobytes(), width0, self.cap),
+        return ((type(self), reordered_vertices.data.tobytes(), width0, self.cap, cap_extensions0),
                 (offset, scale / norm_value, rotation, False),
                 lambda: Path(
                     reordered_vertices * norm_value,
-                    width=self.width * norm_value,
+                    width=width0 * norm_value,
                     cap=self.cap,
+                    cap_extensions=None if cap_extensions0 is None else tuple(v * norm_value for v in cap_extensions0),
                     ))
 
     def clean_vertices(self) -> 'Path':
diff --git a/masque/test/test_autotool_refactor.py b/masque/test/test_autotool_refactor.py
index 677ddd6..d93f935 100644
--- a/masque/test/test_autotool_refactor.py
+++ b/masque/test/test_autotool_refactor.py
@@ -108,6 +108,62 @@ def test_autotool_planS_double_L(multi_bend_tool) -> None:
     assert data.ldata1.straight_length == 0
     assert data.l2_length == 6
 
+
+def test_autotool_planS_pure_sbend_with_transition_dx() -> None:
+    lib = Library()
+
+    def make_straight(length: float) -> Pattern:
+        pat = Pattern()
+        pat.ports["A"] = Port((0, 0), 0, ptype="core")
+        pat.ports["B"] = Port((length, 0), pi, ptype="core")
+        return pat
+
+    def make_sbend(jog: float) -> Pattern:
+        pat = Pattern()
+        pat.ports["A"] = Port((0, 0), 0, ptype="core")
+        pat.ports["B"] = Port((10, jog), pi, ptype="core")
+        return pat
+
+    trans_pat = Pattern()
+    trans_pat.ports["EXT"] = Port((0, 0), 0, ptype="ext")
+    trans_pat.ports["CORE"] = Port((5, 0), pi, ptype="core")
+    lib["xin"] = trans_pat
+
+    tool = AutoTool(
+        straights=[
+            AutoTool.Straight(
+                ptype="core",
+                fn=make_straight,
+                in_port_name="A",
+                out_port_name="B",
+                length_range=(1, 1e8),
+                )
+            ],
+        bends=[],
+        sbends=[
+            AutoTool.SBend(
+                ptype="core",
+                fn=make_sbend,
+                in_port_name="A",
+                out_port_name="B",
+                jog_range=(0, 1e8),
+                )
+            ],
+        transitions={
+            ("ext", "core"): AutoTool.Transition(lib.abstract("xin"), "EXT", "CORE"),
+            },
+        default_out_ptype="core",
+        )
+
+    p, data = tool.planS(15, 4, in_ptype="ext")
+
+    assert_allclose(p.offset, [15, 4])
+    assert_allclose(p.rotation, pi)
+    assert data.straight_length == 0
+    assert data.jog_remaining == 4
+    assert data.in_transition is not None
+
+
 def test_renderpather_autotool_double_L(multi_bend_tool) -> None:
     tool, lib = multi_bend_tool
     rp = RenderPather(lib, tools=tool)
diff --git a/masque/test/test_library.py b/masque/test/test_library.py
index 0a04d98..e58bd10 100644
--- a/masque/test/test_library.py
+++ b/masque/test/test_library.py
@@ -6,6 +6,7 @@ from ..pattern import Pattern
 from ..error import LibraryError, PatternError
 from ..ports import Port
 from ..repetition import Grid
+from ..shapes import Path
 from ..file.utils import preflight
 
 if TYPE_CHECKING:
@@ -243,3 +244,18 @@ def test_library_get_name() -> None:
 
     name2 = lib.get_name("other")
     assert name2 == "other"
+
+
+def test_library_dedup_shapes_does_not_merge_custom_capped_paths() -> None:
+    lib = Library()
+    pat = Pattern()
+    pat.shapes[(1, 0)] += [
+        Path(vertices=[[0, 0], [10, 0]], width=2, cap=Path.Cap.SquareCustom, cap_extensions=(1, 2)),
+        Path(vertices=[[20, 0], [30, 0]], width=2, cap=Path.Cap.SquareCustom, cap_extensions=(3, 4)),
+        ]
+    lib["top"] = pat
+
+    lib.dedup(norm_value=1, threshold=2)
+
+    assert not lib["top"].refs
+    assert len(lib["top"].shapes[(1, 0)]) == 2
diff --git a/masque/test/test_pack2d.py b/masque/test/test_pack2d.py
index 5390a4c..914c23e 100644
--- a/masque/test/test_pack2d.py
+++ b/masque/test/test_pack2d.py
@@ -1,4 +1,4 @@
-from ..utils.pack2d import maxrects_bssf, pack_patterns
+from ..utils.pack2d import maxrects_bssf, guillotine_bssf_sas, pack_patterns
 from ..library import Library
 from ..pattern import Pattern
 
@@ -25,6 +25,34 @@ def test_maxrects_bssf_reject() -> None:
     assert 0 not in rejects
 
 
+def test_maxrects_bssf_exact_fill_rejects_remaining() -> None:
+    rects = [[20, 20], [1, 1]]
+    containers = [[0, 0, 20, 20]]
+
+    locs, rejects = maxrects_bssf(rects, containers, presort=False, allow_rejects=True)
+
+    assert tuple(locs[0]) == (0.0, 0.0)
+    assert rejects == {1}
+
+
+def test_maxrects_bssf_presort_reject_mapping() -> None:
+    rects = [[10, 12], [19, 14], [13, 11]]
+    containers = [[0, 0, 20, 20]]
+
+    _locs, rejects = maxrects_bssf(rects, containers, presort=True, allow_rejects=True)
+
+    assert rejects == {0, 2}
+
+
+def test_guillotine_bssf_sas_presort_reject_mapping() -> None:
+    rects = [[2, 1], [17, 15], [16, 11]]
+    containers = [[0, 0, 20, 20]]
+
+    _locs, rejects = guillotine_bssf_sas(rects, containers, presort=True, allow_rejects=True)
+
+    assert rejects == {2}
+
+
 def test_pack_patterns() -> None:
     lib = Library()
     p1 = Pattern()
@@ -49,3 +77,20 @@ def test_pack_patterns() -> None:
     # p1 size 10x10, effectively 12x12
     # p2 size 5x5, effectively 7x7
     # Both should fit in 20x20
+
+
+def test_pack_patterns_reject_names_match_original_patterns() -> None:
+    lib = Library()
+    for name, (lx, ly) in {
+            "p0": (10, 12),
+            "p1": (19, 14),
+            "p2": (13, 11),
+            }.items():
+        pat = Pattern()
+        pat.rect((1, 0), xmin=0, xmax=lx, ymin=0, ymax=ly)
+        lib[name] = pat
+
+    pat, rejects = pack_patterns(lib, ["p0", "p1", "p2"], [[0, 0, 20, 20]], spacing=(0, 0))
+
+    assert set(rejects) == {"p0", "p2"}
+    assert set(pat.refs) == {"p1"}
diff --git a/masque/test/test_path.py b/masque/test/test_path.py
index 766798f..1cdd872 100644
--- a/masque/test/test_path.py
+++ b/masque/test/test_path.py
@@ -1,4 +1,4 @@
-from numpy.testing import assert_equal
+from numpy.testing import assert_equal, assert_allclose
 
 from ..shapes import Path
 
@@ -79,3 +79,33 @@ def test_path_scale() -> None:
     p.scale_by(2)
     assert_equal(p.vertices, [[0, 0], [20, 0]])
     assert p.width == 4
+
+
+def test_path_scale_custom_cap_extensions() -> None:
+    p = Path(vertices=[[0, 0], [10, 0]], width=2, cap=Path.Cap.SquareCustom, cap_extensions=(1, 2))
+    p.scale_by(3)
+
+    assert_equal(p.vertices, [[0, 0], [30, 0]])
+    assert p.width == 6
+    assert p.cap_extensions is not None
+    assert_allclose(p.cap_extensions, [3, 6])
+    assert_equal(p.to_polygons()[0].get_bounds_single(), [[-3, -3], [36, 3]])
+
+
+def test_path_normalized_form_preserves_width_and_custom_cap_extensions() -> None:
+    p = Path(vertices=[[0, 0], [10, 0]], width=2, cap=Path.Cap.SquareCustom, cap_extensions=(1, 2))
+
+    intrinsic, _extrinsic, ctor = p.normalized_form(5)
+    q = ctor()
+
+    assert intrinsic[-1] == (0.2, 0.4)
+    assert q.width == 2
+    assert q.cap_extensions is not None
+    assert_allclose(q.cap_extensions, [1, 2])
+
+
+def test_path_normalized_form_distinguishes_custom_caps() -> None:
+    p1 = Path(vertices=[[0, 0], [10, 0]], width=2, cap=Path.Cap.SquareCustom, cap_extensions=(1, 2))
+    p2 = Path(vertices=[[0, 0], [10, 0]], width=2, cap=Path.Cap.SquareCustom, cap_extensions=(3, 4))
+
+    assert p1.normalized_form(1)[0] != p2.normalized_form(1)[0]
diff --git a/masque/test/test_pather_api.py b/masque/test/test_pather_api.py
index 9ac1b78..c837280 100644
--- a/masque/test/test_pather_api.py
+++ b/masque/test/test_pather_api.py
@@ -1,7 +1,9 @@
+import pytest
 import numpy
 from numpy import pi
 from masque import Pather, RenderPather, Library, Pattern, Port
 from masque.builder.tools import PathTool
+from masque.error import BuildError
 
 def test_pather_trace_basic() -> None:
     lib = Library()
@@ -240,3 +242,31 @@ def test_pather_trace_into() -> None:
     assert numpy.allclose(p.pattern.ports['G'].offset, (-10000, 2000))
     assert p.pattern.ports['G'].rotation is not None
     assert numpy.isclose(p.pattern.ports['G'].rotation, pi)
+
+
+def test_pather_jog_failed_fallback_is_atomic() -> None:
+    lib = Library()
+    tool = PathTool(layer='M1', width=2, ptype='wire')
+    p = Pather(lib, tools=tool)
+    p.pattern.ports['A'] = Port((0, 0), rotation=0, ptype='wire')
+
+    with pytest.raises(BuildError, match='shorter than required bend'):
+        p.jog('A', 1.5, length=5)
+
+    assert numpy.allclose(p.pattern.ports['A'].offset, (0, 0))
+    assert p.pattern.ports['A'].rotation == 0
+    assert len(p.paths['A']) == 0
+
+
+def test_pather_uturn_failed_fallback_is_atomic() -> None:
+    lib = Library()
+    tool = PathTool(layer='M1', width=2, ptype='wire')
+    p = Pather(lib, tools=tool)
+    p.pattern.ports['A'] = Port((0, 0), rotation=0, ptype='wire')
+
+    with pytest.raises(BuildError, match='shorter than required bend'):
+        p.uturn('A', 1.5, length=0)
+
+    assert numpy.allclose(p.pattern.ports['A'].offset, (0, 0))
+    assert p.pattern.ports['A'].rotation == 0
+    assert len(p.paths['A']) == 0
diff --git a/masque/test/test_renderpather.py b/masque/test/test_renderpather.py
index ee04671..3ad0d95 100644
--- a/masque/test/test_renderpather.py
+++ b/masque/test/test_renderpather.py
@@ -119,3 +119,14 @@ def test_renderpather_rename_port(rpather_setup: tuple[RenderPather, PathTool, L
     assert_allclose(path_shape.vertices, [[0, 0], [0, -10], [0, -20]], atol=1e-10)
     assert "new_start" in rp.ports
     assert_allclose(rp.ports["new_start"].offset, [0, -20], atol=1e-10)
+
+
+def test_pathtool_traceL_bend_geometry_matches_ports() -> None:
+    tool = PathTool(layer=(1, 0), width=2, ptype="wire")
+
+    tree = tool.traceL(True, 10)
+    pat = tree.top_pattern()
+    path_shape = cast("Path", pat.shapes[(1, 0)][0])
+
+    assert_allclose(path_shape.vertices, [[0, 0], [10, 0], [10, 1]], atol=1e-10)
+    assert_allclose(pat.ports["B"].offset, [10, 1], atol=1e-10)
diff --git a/masque/utils/pack2d.py b/masque/utils/pack2d.py
index a99b01e..248f408 100644
--- a/masque/utils/pack2d.py
+++ b/masque/utils/pack2d.py
@@ -60,6 +60,12 @@ def maxrects_bssf(
         degenerate = (min_more & max_less).any(axis=0)
         regions = regions[~degenerate]
 
+        if regions.shape[0] == 0:
+            if allow_rejects:
+                rejected_inds.add(rect_ind)
+                continue
+            raise MasqueError(f'Failed to find a suitable location for rectangle {rect_ind}')
+
         ''' Place the rect '''
         # Best short-side fit (bssf) to pick a region
         region_sizes = regions[:, 2:] - regions[:, :2]
@@ -102,7 +108,7 @@ def maxrects_bssf(
     if presort:
         unsort_order = rect_order.argsort()
         rect_locs = rect_locs[unsort_order]
-        rejected_inds = set(unsort_order[list(rejected_inds)])
+        rejected_inds = {int(rect_order[ii]) for ii in rejected_inds}
 
     return rect_locs, rejected_inds
 
@@ -187,7 +193,7 @@ def guillotine_bssf_sas(
     if presort:
         unsort_order = rect_order.argsort()
         rect_locs = rect_locs[unsort_order]
-        rejected_inds = set(unsort_order[list(rejected_inds)])
+        rejected_inds = {int(rect_order[ii]) for ii in rejected_inds}
 
     return rect_locs, rejected_inds